Project work,Entrepreneurship,Environment and Disastermanagement
** 3 25 75 100 50
2 12067Industrial training II(Report writing & Vivavoce)
- 3 # 25 75 100 50
** To be completed during Industrial training# Industrial training-II Board Examination will be conducted after completion ofSix months Industrial training
10
Curriculum and Scheme of ExaminationDiploma in Mechanical Engineering (Part Time) (Course no: 3020)
K-Scheme (With effect from 2008-2009)
Total Curriculum Hours: 18 Hours / Week Total Working Hours :18 Hours / Week
Define various mechanical properties of materials. Calculate the deformation of materials, which are subjected to axial load and
shear. Determine the moment of Inertias of various section used in the Industry. Estimate the stresses induced in thin and thick cylinder under internal
pressure Draw the Graphical representation of shear force and bending moment of the
beam subjected to different loads. Construct SFD and BMD. Calculate the power transmitted by the solid & hollow shafts. Distinguish different types of spring and their applications. Define types of friction. Describe the power transmission by the belt, chain and gear drives.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations
12031- Mechanics
of Materials
Hours/Wee
k
Hours/Semeste
r
Assessment Marks
6 96
Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
Unit Topic TIME (Hrs)I. Mechanical properties of materials and Simple stresses
and strains18
II. Geometrical properties of sections and Thin cylindersand thin spherical shells
18
III. Shear force and Bending moment diagrams and Theoryof Simple bending
18
IV. Torsion and Springs 18V. Deflection of beams, Friction, Gear drives and Belt
drives18
Revision and test 6TOTAL 96
15
UNIT I MECHANICAL PROPERTIES OF MATERIALS AND SIMPLE STRESSESAND STRAINS 18 Hrs
Mechanical properties of materials:Introduction - Definition of mechanical properties such as strength – elasticity,plasticity, ductility, malleability, stiffness, toughness, brittleness, hardness, wearresistance, machinability, cast ability and weld ability – Fatigue, Fatigue strength,creep – temperature creep – cyclic loading and repeated loading – endurance limit.Simple stresses and strains:Introduction – Definition – Load, stress and strain – Classification of force systems –tensile, compressive and shear force systems – Behavior of mild steel in tension uptorupture – Stress – Strain diagram – limit of proportionality – elastic limit – yield stress– breaking stress – Ultimate stress – percentage of elongation and percentagereduction in area – Hooke’s law – Definition – Young’s modulus working stress, factorof safety, load factor, shear stress and shear strain modulus of rigidity.
Linear strain – Deformation due to tension and compressive force – Simple problemsin tension, compression and shear force.Definition – Lateral strain – Poisson’s ratio – volumetric strain – bulk modulus –volumetric strain of rectangular and circular bars – problems connecting linear, lateraland volumetric deformation – Elastic constants and their relationship ( No derivation )– Problems on elastic constants.Definition – Composite bar – Problem in composite bars subjected to tension andcompression – Temperature stresses and strains – Simple problems – Definition –strain energy – proof resilience – modulus of resilience – The expression for strainenergy stored in a bar due to Axial load ( no Derivation ) – Instantaneous stressesdue to gradual, sudden, impact and shock loads – Problems computinginstantaneous stress and deformation in gradual, sudden, impact and shockloadings.
UNIT II GEOMETRICAL PROPERTIES OF SECTIONS AND THIN CYLINDERSAND THIN SPHERICAL SHELLS 18hrs
Geometrical properties of sections:Introduction – definition – center of gravity and centroid-position of centroids of planegeometrical figures such as rectangle, triangle, circle and trapezium-problems todetermine the centroid of angle, channel, T and I sections only (No problems onremoved sections)- Definition-centroidal axis-Axis of symmetry. Moment of Inertia –Statement of parallel axis theorem and perpendicular axis theorem. (No derivation)-moment of Inertia of lamina of rectangle, circle, triangle, I and channel sections-(Noderivations)-Definition-Polar moment of Inertia-radius of gyration – Problemscomputing moment of inertia and radius of gyration for angle, T, Channel and Isections.(No problems on removed sections).Thin Cylinders and Thin Spherical Shells:Introduction – Definition – Thin and thick cylindrical shell – Failure of thin cylindricalshell subjected to internal pressure – Derivation of Hoop and longitudinal stresscauses in a thin cylindrical shell subjected to internal pressure – simple problems –change in dimensions of a thin cylindrical shell subjected to internal pressure –problems – Derivation of tensile stress induced is a thin spherical shell subjected tointernal pressure – simple problems – change in diameter and volume of a thinspherical shell due to internal pressure – problems.
16
UNIT III SHEAR FORCE AND BENDING MOMENT DIAGRAMS AND THEORY OFSIMPLE BENDING 18hrsShear force and Bending moment diagrams:Introduction – classification of beams – Definition – shear force and Bending moment– sign conventions for shear force and bending moment – types of loadings –Relationship between load, force and bending moment at a section – shear forcediagram and bending moment diagram of cantilever and simple supported beamsubjected to point load and uniformly distributed load – Determination of Maximumbending moment in cantilever beam and simple supported beam when they aresubjected to point load and uniformly distributed load.Theory of simple bending:Introduction – theory of simple bending – Assumptions – Neutral axis – bendingstress distribution – moment of resistance – bending equation – M/I=f/y=E/R(NoDerivation) – Definition – section modulus - rectangular and circular sections –strength of beam – simple problems involving flexural formula for cantilever andsimple supported beam.
UNIT IV TORSION AND SPRINGS 18hrs
TorsionIntroduction – theory of torsion – Assumptions – torsion equation – T/J=fs/R=Cθ/l(No Derivation) – strength of solid and hollow shafts – power transmitted – Definition –Polar modulus – Torsional rigidity – strength and stiffness of shafts – comparison ofhollow and solid shafts in weight and strength considerations – Advantages of hollowshafts over solid shafts – Problems.SpringsIntroduction – Types of springs – Laminated and coiled springs – Types of coiledsprings – Difference between open and closely coiled helical springs – closely coiledhelical spring subjected to an axial load – problem to determine shear stress,deflection, stiffness and resilience of closed coiled helical springs.
UNIT V DEFLECTION OF BEAMS, FRICTION, GEAR DRIVES AND BELTDRIVES 18hrs
Deflection of beams:Introduction – Definition – slope, deflection, stiffness and flexural rigidity –Derivations of relationship between slope, Deflection and Radius of curvature –Derivation of slope and deflections of cantilever and simply supported beam by areamoment method under point load and UDL– simple problems.Friction:Introduction – Definition – Force of friction – Limiting friction – Static Friction –Dynamic friction – Angle of friction – co-efficient of friction – cone of friction – Laws ofstatic and dynamic friction.Gear drives and Belt Drives:Introduction – classification of gears – Nomenclature of a gear – Explanation andapplication of spur, helical and bevel gears, worm and worm wheel, rack and pinion –Velocity ratio of a gear drive – merits and demerits of gear drive – problems onsimple gear train and Power transmitted by gear.Belt drive – types-open belt drive – cross belt drive – flat belt drive – v belt drive -problems on power transmitted. (Problems not involving centrifugal tension Conditionfor maximum power transmission and initial tension).
17
Revision and Test 6Hrs
Text Books:
1. A. K. Upadhyay, Applied Mechanics, pyblished by Charotar PublishingHouse, Opp. Amul Dairy, Court Road, Anand 388 001, India 2002.
2. R. S. Khurmi, Strength of Materials, S.Chand & Co., Ram Nagar, NewDelhi – 2002.
2. S. Ramamrutham, Strength of Materials, 15th Edn 2004, Dhanpat Rai Pub.Co., New Delhi.
18
12031 MECHANICS OF MATERIALSMODEL QUESTION PAPER – I
DURATION: 3 HRS. MAX. MARKS: 75
NOTE: Answer all the questions in Part – A. Each carries one mark.Answer all the questions in Part – B. Each carries threemarks.Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART – A Answer all the questions 1x10=10
1. Define elasticity.2. Define load factor.3. Define centroid.4. What is the relation between hoop and longitudinal stress.5. Define neutral axis.6. List the types of loads acting on beam.7. How do you classify the springs.8. Define torsional rigidity.9. Define slope.10. What is limiting friction.
PART – B Answer all the questions 3x5=15
11. If the ultimate shear stress for mild steel is 300 N/mm2. Find the forcerequired to punch a 13mm diameter hole in a mild steel plate 10mm thick.
12. A channel section is of size 300 100mm overall. The base as well as theflanges of the channel are 10mm thick. Find the centroid about x-x axis.
13. Draw the shear force and bending moment diagram of a cantilever beam witha point load of 50KN at free end. The length of the beam is 8m.
14. State the assumptions made in theory of pure torsion.15. Explain angle of friction.
PART – C Answer any one question from each unit.10x5=50
16. 1. A steel tube 100mm internal diameter and 12.5mm thick is surrounded by abrass tube of the same thickness in such a way that the axis of the two tubescoincide. The compound tube is loaded by an axial compressive load of 5KN.Determine the load carried by each tube. Assume that there is no bucking ofthe tube. Take Young’s modulus for steel as 200 KN/mm2 and that for brass is100 KN/mm2. Tubes are of same length. (10)
OR2. A bar of steel 28mm diameter and 250mm long is subjected to an axial load
of 80KN. It is found that the diameter has contracted by 1/240 mm. If themodulus of rigidity is 80 KN/mm2. Calculate i)Poissons ratio.ii)Youngs modulus and Bulk modulus. (10)
17. 1. Find Ixx and Iyy for the T section flange of 150mm and overall depth of250mm with the thickness of 20mm for both web and flange. (10)
19
OR2. A Cylindrical shell 2.4m long, 600mm in diameter is made up of 15mm thick
plates. Find the changes in length, diameter and volume of the cylinder whenthe shell is subjected to an internal pressure of 2N/mm2 , E= 200 KN/mm2 ,1/m=0.3. (10)
18. 1. A beam 8m long is simply supported at its ends. It carries an udl of 1KN/mrun over the length of left half of its span, together with concentrated loads 2,3 and 2KN Situated at 2, 4 and 6m respectively from the left hand support.
(10)OR
2. A rectangular beam of 200mm deep and 100mm wide is simply supportedover a span of 8m and carries a central point load of 25KN. Determine themaximum stress in the beam. Also calculate the values of longitudinal fibrestress at a distance of 25mm from the top surface of the beam. (10)
19. 1. (a)Write the difference between open and closed coil helical springs. (4)
(b)A closed coiled helical spring made of steel wire 100mm diameter has 10coils of 120mm mean diameter, calculate the deflection under an axial loadof 100N, what is the stiffness of the spring? Take C=1.2MPa. (6)
OR2. A solid shaft has to transmit 10KW at 210r.p.m. The maximum torque in each
revolution exceeds the mean by 30%. If the shear stress is not to exceed80Mpa find a suitable diameter of the solid shaft, Calculate the angle of twistfor a length of 2m. C=0.8x105N/mm2. (10)
20. 1. (a) State the laws of static friction. (4)
(b) A 3m cantilever beam supports a concentrated load of 10KN at the freeend. E=2x105N/mm2. and I= 20x106mm4.Compute the maximum slope &deflection. (6)
OR2. An open belt drive 100mm wide connects pulleys mounted on parallel shaft
2.5m apart. The diameter of larger pulley is 300mm and that smaller pulley150mm. The bigger pulley is rotating at 120r.p.m. If the permissible tensionin the belt is Limited is 14N/mm width. Find the power that can betransmitted at this speed. Take coefficient of friction is 0.3. (10)
20
12031 MECHANICS OF MATERIALSMODEL QUESTION PAPER – II
DURATION : 3 HRS. MAX. MARKS:75
NOTE: Answer all the questions in Part – A. Each carries one mark.Answer all the questions in Part – B. Each carries three marks.
Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART – A Answer all the questions 1x10=101. Define Creep.2. Define resilience.3. Define axis of symmetry.4. Write the formula for lateral strain in thin cylinders.5. Define section modulus.6. Write any two differences between closed and open coil helical spring.7. At maximum bending moment what will be the value of shear force?8. What type of stress will be developed in the neutral layer axis when it is
subjected to bending load?9. Define deflection.10. Define circular pitch.
PART – B Answer all the questions 3x5=1511. Calculate the strain energy that can be stored in a steel bar 40mm in diameter
and 3m long subjected to a pull of 100KN. Take E = 200 KN/mm2
12. State Hoop stress and Longitudinal stress.13. Define Shear force and bending moment of a beam.14. Calculate the torque transmitted by a shaft of 100mm diameter running at
250r.p.m. If the shear stress in the shaft material is not to exceed 75MPa.15. Explain about cone of friction.
PART – C Answer any one question from each unit.10x5=5016. 1. A steel specimen 150mm2 in cross section stretches by 0.05mm over a
50mm gauge length under an axial load of 30KN. Calculate the strain energystored in the specimen at this stage. If the load at the elastic limit for thespecimen is 50KN. Calculate the elongation at elastic limit and proofresilience. (10)
OR2. (a) Draw stress strain diagram and mark the salient points. (5)
(b) A steel wire 10m long and 3m diameter is subjected to pull of 600N.Calculate (i) stress (ii) the elongation if E=2x105N/mm2. and (ii) factor ofsafety if the tensile strength is 500MPa. (5)
17. 1. A long steel tube 70mm internal diameter and wall thickness 2.5mm hasclosed ends and is subjected to an internal pressure of 10 N/mm2. Calculatethe magnitude of hoop and longitudinal stress set up in the tube. If theefficiency of the longitudinal joint is 80%. Which stress is affected and what isits revised value. (10)
OR2. Determine the moment of inertia about centroidal coordinate axis of an I-
section having equal flanges 120x20mm size and web 120x20mm thick.(10)
21
18. 1. A simply supported beam of effective span 6m carries three point loads of 30KN, 25KN and 40KN at 1m, 3m and 4.5m respectively from the left support.Draw the SFD and BMD diagram. (10)
OR2. A cast iron water pipe 450mm bore and 25mm thick is supported at two points
9m apart. Find the maximum stress in the metal a) when it is running full, b)when it is empty. Specific weight of cast iron is 78KN/m3 and that of water is10 KN/m3 . (10)
19. 1. a) Write the assumptions made in theory of pure torsion. (4)
b) A solid circular shaft has to transmit a power of 40KW at 120r.p.m.. Thepermissible shear stress is 100N/mm2 , determine the diameter of the shaftif the maximum torque exceeds the mean torque by 25%. (6)
OR2. A truck weighing 30KN and moving at 5Km/hr has to be brought to rest by a
Buffer. Find how many springs each of 18 coils will be required to store theenergy of motion during compression of 200mm. The spring is made out of25mm diameter steel rod coiled to a mean diameter of 240mm. TakeN=0.84x105 N/mm2 . (10)
20. 1. A cantilever beam of length 3m is carrying a uniformly distributed load of wKN./m. Assuming rectangular cross section with depth equal to twice thewidth, determine the dimensions of the beam so that the vertical deflection atfree end does not exceed 8mm. Take maximum bending stress is 100 N/mm2
, and E= 2x105 N/mm2 . (10)OR
2. A train of wheel transmit 3KW. The driving pinion has 20 teeth of 25mm pitch.Calculate the speed in r.p.m. for the pinion, if the pressure between the teethexerted is not to be exceed 600N. (10)
22
12032 MANUFACTURING PROCESS
5 Hrs/Week 16 Weeks /Sem.Total Hrs : 80
OBJECTIVE: Acquire Knowledge about types of pattern, casting, moulding. Explain hot working and cold working processes Describe the various casting processes Appreciate the safety practices used in welding. Explain powder metallurgy process Distinguish the different heat treatment processes Explain the lathe and its working parts. Describe the functioning of semi automatic and automatic lathes. Compare the various types of gauges used in metrology Compare the various types of linear and angle measuring devices.
SCHEME OF INSTRUCTION AND EXAMINATIONSubject Instruction Examination
12032
Manufacturin
g Process
Hour/Week Hours/Semest
er
Assessment Marks
5 80
Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATIONUNIT TOPIC TIME ( Hours )
I. Foundry 15
II. Forging and Welding 15
III. Powder Metallurgy and Heat Treatment 15
IV. Lathe Work, Semi Automatic and Automatic Lathes 15
V. Metrology and Theory of Metal cutting 15
Revision Test 5
Total 80
UNIT – I FOUNDRY 15hrs
PATTERNS – definition – pattern materials – factors for selecting patternmaterials – single piece solid, split patterns – pattern allowances – core prints.MOULDING – definition – moulding boxes, moulding sand – ingredients – silica –clay – moisture and miscellaneous materials – properties of moulding sand –sand additives – moulding sand preparation – mixing – tempering andconditioning – types of moulding – green sand – dry sand – machine moulding –Top and bottom squeezer machines – Jolting machines – sand slinger- core –CO2 process core making – types of core – core boxes.
23
CASTING – definition – sand casting using green sand and dry sand – gravity diecasting – pressure die casting – hot and cold- chamber processes – centrifugalcasting – continuous casting – chilled casting – malleable casting – melting ofcast iron – cupola furnace – melting of non ferrous metals – crucible furnacemelting of steel and arc furnaces – induction furnaces – instrument for measuringtemperature – optical pyrometer – thermo electric pyrometer – cleaning of casting– tumbling, trimming, sand and shot blasting – defects in casting – causes andremedies – safety practices in foundry.
UNIT – II FORGING AND WELDING 15hrsHot working, cold working – advantages of hot working and cold working– hotworking operations – rolling – forging, smith forging, drop forging, upset forging,press forging – roll forging.Welding – arc welding definition – arc welding equipment – arc welding methods– carbon arc, metal arc, Metal Inert gas (MIG), Tungsten inert gas (TIG), Atomichydrogen, Plasma arc, Submerged arc and Electro slag welding, Gas welding –definition Gas Welding Equipment– oxy – acetylene welding Three types offlame– resistance welding – definition – classification of resistance welding – butt– spot – seam – projection welding – welding related processes – oxy –acetylene cutting – arc cutting – hard facing bronze welding – soldering andbrazing special welding processes – cast iron welding – thermit welding – solidslate welding, ultrasonic, diffusion and explosive welding – explosive cladding –modern welding, electron beam and laser beam welding – types of welded joints– merits and demerits of welded joints – inspection and testing of welded joints –destructive and non destructive types of tests – magnetic particle test –radiographic and ultrasonic test defects in welding – causes and remedies –safety practices in welding .
UNIT – III POWDER METALLURGY AND HEAT TREATMENT 15 hrsMethods of manufacturing metal powders – atomization, reduction andelectrolysis deposition – compacting – sintering – sizing – infiltration – mechanicalproperties of parts made by powder metallurgy – design rules for the powermetallurgy process.Heat treatment processes – purpose – procedures – applications of various heattreatment processes – Iron – carbon equilibrium diagram – full annealing –process annealing stress relief annealing - spherodising annealing – isothermalannealing – normalizing – hardening – tempering – quenching medium – differenttypes and their relative merits – case hardening – pack carburizing – cyaniding –nitriding – induction hardening and flame hardening.
UNIT – IV LATHE WORK, SEMI AUTOMATIC AND AUTOMATIC LATHES15hrs
Theory of lathes – specifications – simple sketches – principal parts – head stock– back geared type – all geared type – tumbler gear mechanism – quick changegear box – apron mechanism – carriage cross slide – automatic, longitudinal andcross feed mechanism – tail stock and its functions – work holding device – faceplate – three jaw chuck – four jaw chuck – catch plate and carrier – types ofcentres – machining operations done on lathe straight turning – step turning-taper turning-knurling-Thread cutting-Facing-Boring-chamfering– latheattachments – tool post grinders – milling attachments-cutting speed-feed-depthof cut.Semi automatic lathes:Types of semi automatic lathes – capstan and turret lathes – difference betweenturret and capstan – tools and work holding devices – self opening die head –collapsible taps – simple tool lay out – process sheet.
24
Automatic Lathes:Automatic lathe – classification of single spindle automatic lathe – principle ofautomatic lathes – automatic screw cutting machines – multi spindle automaticlathes – use of cams in automats.
UNIT – V METROLOGY AND THEORY OF METAL CUTTING 15 HrsMetrology, Micrometer – inside and outside vernier caliper-digital vernier-digitalmicrometer – vernier height gauge – digital type vernier micrometers – depthgauges – applications – plug and ring gauges – snap gauges – threadmicrometers – gear tooth vernier – bevel protractor – slip gauges – sine bar –comparators – mechanical (dial gauges) – electrical, optical and pneumaticcomparators – profile measurements – optical flat – surface finish measurements– profilometers.Cutting tool material-High carbon Steel-High Speed Steel-Stellites-Cementedcarbides-ceramics-Composition and applications for the above-Single pointcutting tool-nomenclature-tool life-Chip Breakers.
Revision and Test 5Hrs
Text Books:
1. Hajra Chowdry & Bhattacharaya, Elements of workshop TechnologyVolume I & II, Edn. XI, Media Promoters & Publishers Pvt. Ltd., SeewaiBuilding `B’, 20-G, Noshir Bharucha Marg, Mumbai 400 007 – 2007.
2. R. S. Khurmi & J. K. Gupta, A Text book of workshop Technology, Edn. 2,S.Chand & Co., Ram Nagar, New Delhi - 2002.
Reference Books:
1. Begeman, Manufacturing process, Edn. 5, McGraw Hill, New Delhi1981.
2. WAJ Chapman, Workshop Technology, Volume I, II, & III, Vima Books Pvt.Ltd., 4262/3, Ansari Road, Daryaganj, New Delhi 110 002.
3. Raghuwanshi, Workshop Technology, Khanna Publishers.Jain & Gupta, Production Technology, Edn. XII, Khanna Publishers, 2-B,North Market, NAI Sarak, New Delhi 110 006 - 2006
4. P. C. SHARMA, Production Technology, Edn. X, S.Chand & Co. Ltd., RamNagar, New Delhi 110 055 - 2006
5. HMT, Production Technology, Edn. 18, published by Tata McGraw Hillpublishing Co. Ltd.,7 West Patel Nagar, New Delhi 110 008. – 2001.
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B (3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART-A Answer all the questions 1x10=10
1. What is core?2. What are the advantages of wooden pattern?3. What is Hot Working?4. List out the equipment used in gas welding.5. What is compacting in powder metallurgy process?6. What is case hardening?7. What are functions of a tumbler gear mechanism?8. What are functions of a turret in a capstan lathe?9. What is measuring instrument?10. What for the snap gauges are used?
PART-B Answer all the questions 3x5=15
11. List out the types of pattern. Explain any 2 types of pattern.12. What are advantages of Press forging?13. What are advantages of powder metallurgy components?14. Write the specification of a lathe.15. What are properties of a cutting tool material?
PART-C Answer any one question from each unit.10x5=50
16. 1. a) List out the pattern allowance. Explain? (5)b) Explain with a meat sketch jolt moulding machine (5)
OR2. a) Sketch a cupola and label the Principal parts (5)
b) Explain the safety precautions practical in a foundry shop (5)
17. 1. a) Explain with a neat sketch the drop forging process. (5)b) Explain with a neat sketch the explosive welding (5)
OR2. a) Explain with a neat sketch the TIG welding processes. Write its (6)
application.b) What are advantages of press forging processes? (4)
18. 1. What are the different methods of manufacturing powders in powdermetallurgy processes? Explain. OR
(10)2. a) What is annealing? Explain Full annealing process. (5)
b) What are the purposes for heat treatment of metals? (5)
19. 1. a) Explain with a neat sketch the all geared head stock of a lathe. (6)b) Explain with a neat sketch the self-opening die head. (4)
OR
26
2. a) List out the work holding devices used in a lathe. Explain with neat sketchany one work holding devices. (5)
b) Tool schedule and process chart for manufacturing of a belt in a Semiautomatic lathe. (5)
20. 1. a) Explain with a neat sketch the profilometer. (5)b) Sketch and nomenclature of a single point cutting tool. (5)
OR2. a) Explain with a neat sketch the optical comparators. Write its advantages.
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART – A Answer all the questions 1x10=10
1. What is pattern?2. What is the function of a optical pyrometer?3. List out the hand tool used in smith forging.4. List the equipment used in Arc welding.5. What is sintering in powder metallurgy process?6. What are the quenching mediums used in heat treatment processes?7. What are the functions of a lead screw?8. What are functions of a cam in automatic lathe?9. What is least count of a measuring instrument?10. What are compositions of a satellite tool?
PART-B Answer all the questions 3x5=15
11. What are the properties of a good moulding sand? Explain.12. Differentiate between hot working and cold working.13. What are the different methods of manufacturing powders in powder
metallurgy processes? Explain any one method.14. Differentiate between capstan lathe and turret lathe.15. Explain with a sketch the vernier caliper.
PART-C Answer any one question from each unit 10x5=50
16. 1. a) Explain with neat sketch co2 process of core making. (5)b) Explain with neat sketch the pressure die casting process. (5)
OR2. a) What are the different casting defects? Explain its causes and remedies.
(10)
17. 1. Explain with neat sketch submerged Arc welding. Write its advantages anddisadvantages. (10)
OR2. a) What are the 3 types of flame used in gas welding? Write its Application?
(6)b) Explain with sketch the drop forging processes (4)
18. 1. Sketch the iron-carbon equilibrium diagram. Write its different phasetransformation. (10)
OR2. a) What are the advantages of powder metallurgy components? (5)
b) What are the design rules to consider for metallurgy components? (5)
28
19. 1. What are the operations done on a lathe? Explain with a neat sketch any twomethods of taper turning in a lathe. (10)
OR2. a) Explain with neat sketch the single spindle automatic lathe. (5)
b)What are the different work holding devices used in semi automatic lathes?Explain anyone work holding device. (5)
20. 1. a) How to measure the unknown angle by using the sin bar? (4)b) What are the properties of a good cutting tool material? Explain. (6)
ORa) What are the advantages of ceramic tools? (4)b) Explain with a neat sketch the pneumatic comparators. Write its advantages.
29
(6)
12033 FLUID MECHANICS AND FLUID POWER
6 Hrs/Week 16 Weeks / SemTotal Hrs : 96
OBJECTIVES:
Define the properties of Fluids. Explain the working of pressure measuring devices Explain continuity equation and Bernoulli’s Theorem Assess the impact of frictional loss of head in flow through pipes Estimate the discharge through orifices Distinguish the working principles of pumps and turbines. Explain the working of centrifugal pumps and reciprocating pumps. Compare pneumatic system with hydraulic system Draw Pneumatic circuits for industrial application. State the properties of hydraulic Systems Develop hydraulic circuit for machine tools applications.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examination12033 – Fluid
Mechanics and FluidPower
Hours/week Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
TOPIC AND ALLOCATION
UNIT TOPIC TIME(Hrs)
I Properties of Fluids and Pressure Measurements 18II Flow of Fluids and Flow through Pipes 18III Impact of Jets, Hydraulic Turbines, Centrifugal and Reciprocating Pumps 18IV Pneumatic Systems 18V Hydraulic Systems 18
Revision Test 6Total 96
30
UNIT-I PROPERTIES OF FLUIDS AND PRESSURE MEASUREMENTS 18 Hrs.
Introduction-Definition of fluid-Classification of Fluids-ideal and real fluids-Propertiesof a fluid – definition and units.Pressure-units of Pressure-Pressure head-atmospheric, gauge and absolutepressure-problems-Pascal’s law-proof-applications of Pascal’s law-Hydraulic press-Hydraulic jackPressure measurement-Piezometer tube- Simple U-tube manometer-Differential U-tube manometer-Inverted Differential manometer-Micromanometer-Inclined tubemicromanometerMechanical Gauges-Bourdon’s Tube Pressure Gauge-Diaphragm pressure gauge-Dead weight pressure gauge
UNIT-II FLOW OF FLUIDS AND FLOW THROUGH PIPES 18 Hrs.
Types of fluid flow-path line and stream line-mean velocity of flow-discharge of aflowing fluid- equation of continuity of fluid flow-energies of fluid.Bernoulli’s theorem-statement, assumptions and proof-applications and limitations ofBernoulli’s theorem-problems on Bernoulli’s theorem- venturi meter-derivation fordischarge-orifice meter- derivation for discharge-difference between venturimeter and orifice meter-problems on venturimeter and orifice meter - Pitot tube –theory only (no problems)Orifice-types-applications-hydraulic coefficients-determining hydraulic coefficients –problems- discharge through a small orifice discharging freely only-problems –Experimental method of finding Cv, Cc and Cd.
Flow through pipes-laws of fluid friction-hydraulic gradient line-total energy line-wetted perimeter- hydraulic mean radius- loss of head due to friction-Darcy-Weisbach equation and Chezy’s formula-problems-minor losses (description only)-noproblems-Power transmission through pipes- problems.
Impact of jet-on a stationary flat plate held normal to the jet and inclined to thedirection of jet- Impact of jet on a flat plate moving in the direction of jet- Impact of jeton a series of moving plates or vanes-force exerted and work done by the jet-problems.Hydraulic turbines-classifications-Pelton wheel-components and working-speedregulation (theory only)-Francis and Kaplan turbines- components and working-drafttube-functions and types-surge tank-differences between impulse and reactionturbines.Centrifugal Pumps-classifications-construction and working of single stage centrifugalpumps-components with types- theory only-multi stage pumps-advantages-priming –manometric, mechanical, overall efficiencies-definitions only-no problems-cavitation.Reciprocating Pumps- classifications-construction and working of single acting anddouble acting reciprocating pumps-plunger and piston pumps-discharge of areciprocating pump-theoretical power required- coefficient of discharge-slip-problems-negative slip-indicator diagram-separation-air vessel (functions andworking)Special pumps-jet pump-Turbine pump-Submersible pump.
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UNIT-IV PNEUMATIC SYSTEMS 18 Hrs.
Pneumatic Systems- elements-filter-regulator-lubricator unit-pressure control valves-pressure relief valves- pressure regulation valves- directional control valves-3/2 DCV-4/2 DCV – 4/3 DCV – 5/2 DCV – flow control vales – throttle valves –shuttle valves –quick exhaust valves –ISO symbols of pneumatic components – pneumatic circuits –direct control of single acting cylinder – operation of double acting cylinder –operation of double acting cylinder with metering in control - operation of doubleacting cylinder with metering out control – use of shuttle valve in pneumatic circuits –use of quick exhaust valve in pneumatic circuits-automatic operation of double actingcylinder –merits and demerits of pneumatic system-applications.
UNIT-V HYDRAULIC SYSTEMS 18 Hrs.
Hydraulic system-elements-merits and demerits-service properties of hydraulic fluids.Hydraulic accumulator-weighted or gravity type accumulator - spring loaded typeaccumulator-gas filled bladder accumulator-pressure intensifier.Fluid power pumps-external and internal gear pump, vane pump, radial piston pumpISO symbols for hydraulic components –hydraulic circuit using sequencing valve-hydraulic circuit using counter balance valve- hydraulic circuit for shaping machine,table moment in surface grinding machine and milling machine.Comparisons of hydraulic and pneumatic systems.
Revision and Test 6Hrs
Text Books:
1. R.S.Khurmi, A Text Book of Hydraulics, Fluid Mechanics and Hydraulic Machines,Edn. 18, published by S.Chand & Co., Ram Nagar, New Delhi.
2. R.K.Rajput, A Text Book of Hydraulics
Reference Books:
1. Jagadishlal, Hydraulic Machines, 1990, published by Metropolitan Book Co. Pvt.Ltd., 1 Faiz Bazaar, New Delhi – 6.
2. R.K.Bansal, Fluid Mechanics and Hydraulic Machines , Edn. 8, LaxmiPublications P. Ltd., 22 Golden house, Daryaganj, New Delhi 110 002 – 2003.
3. Andrew Parr, Hydraulics and Pneumatics (A Technician’s and Engineer’s Guide)
4. FESTO manual, Fundamentals of Pneumatic control Engineering5. Text book of Hydraulics by H. Meixner and R.Kober, Edn. 1990 published by
FIESTO DIDACTIC KG, D – 7300 Esslingen, 1977, 1988.
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12033 FLUID MECHANICS AND FLUID POWERMODEL QUESTION PAPER – I
DURATION: 3 HRS. MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART-A Answer all the questions 1x10=10
1. Define Specific Gravity.2. State the applications of Pascal’s law.3. Define uniform flow.4. State the applications of Bernoulli’s theorem.5. What is meant by Impact of jet?6. Define Slip.7. What is the use of pressure regulators?8. Name any two types of DCV’s.9. What are the elements of Hydraulic system?
10. What is the purpose of Counter balance valve?
PART-B Answer all the questions 3x5=15
11. One litre of petrol weighs 7N. Calculate its Specific Weight & Density.12. Compare Venturimeter with Orificemeter.13. State the difference between Kaplan turbine & Francis turbine.14. Explain the function of Quick Exhaust Valve.15. List the advantages of Hydraulic system.
PART-C Answer any one question from each unit10x5=50
16. 1. Explain the construction and working principle of Diaphragm type pressuregauge with a simple sketch. (10)
OR2. Explain the simple U- tube Manometer with a neat sketch. (10)
17. 1. State and prove Bernoulli’s theorem. (10)OR
2. Using chezy’s formula, determine the head lost due to friction in a pipe of80mm diameter and length 35m. The velocity of flow is 2m/s. Takechezy’s constant C=0.62. (10)
18. 1. Explain the construction and working principle of Kaplan turbine. (10)OR
2. Explain the working principle of Double Acting Reciprocating pump with aneat sketch. (10)
19. 1. a) Sketch and explain the working of 3/2 DCV (5)b) Sketch and explain the working of shuttle valve (5)
OR
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3. Explain the operation of double acting cylinder with metering out controlwith a circuit diagram.
(10)
20. 1. a) State any four differences between a pneumatic system and hydraulicsystem. (4)
b) Sketch and explain gravity type accumulator(6)
OR2. Draw and explain Hydraulic circuit for Shaping machine. (10)
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12033 FLUID MECHANICS AND FLUID POWERMODEL QUESTION PAPER – II
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Define Viscosity.2. Define Pascal’s law.3. Define Bernoulli’s theorem.4. Define Hydraulic Co-efficient of Velocity.5. Define Impulse Turbine.6. What is meant by Cavitation?7. Draw the ISO symbol for 3/2 DCV.8. Draw the ISO symbol for Shuttle Valve.9. Write any two service properties of Hydraulic fluids.
10. Draw the ISO symbol for Accumulator?
PART-B Answer all the questions 3x5=15
11. A gauge records a pressure of 25KN /m2 . Calculate the correspondingabsolute pressure in KN /m2. The local atmospheric pressure is 760mm ofMercury.
12. Compare Venturimeter with Orificemeter.13. Sketch & explain the Draft tube.14. Sketch & explain the lubricator used in Pneumatic system.15. Write the function of Accumulator used in Hydraulic system?
PART-C Answer any one question from each unit10x5=50
16. 1. a) State the properties of fluid. (4)b) Prove the Pascal's law. (6)
OR2. Sketch & explain the Bourdon tube pressure gauge. (10)
17. 1. Describe with a neat sketch the experimental method of determining the Co-efficient of Contraction.
(10)OR
2. A Venturimeter 0.15m x 0.075m is discharging water. Find the dischargethrough the venturimeter, if the Mercury gauge shows a deflection of 175mmand Co-efficient of the meter is 0.95. (10)
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18. 1. Explain the construction and working of Pelton wheel. (10)OR
2. In a single acting reciprocating pump, the diameter of cylinder is 152mm andthe stroke is 304mm. The water is raised to a height of 18m at a pump speedof 40 rpm. Calculate the theoretical power required and the discharge inlitres/second. If the actual discharge is 0.2122m3/mt. Determine the Co-efficient of discharge and percentage slip. (10)
19. 1. a) Explain 4/3 DCV used in pneumatic system. (5)b) Explain working of quick exhaust valve. (5)
OR2. Explain the operation of double acting cylinder with metering in control with a
circuit diagram.
20. 1. Sketch and explain Gear pump. (10)OR
2. Draw and explain hydraulic circuit for table movement in surface grindingmachine. (10)
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12034 MACHINE DRAWING - CAD
8 Hrs/Week 16 Weeks /SemTotal Hrs : 128
OBJECTIVES:
Appreciate the need of sectional view and types of sections. Draw sectional views using different types of sections. Explain the use of threaded fasteners and the types of threads. Compare hole basis system with shaft basis system. Select different types of fits and tolerance for various types of mating parts. Practice on AutoCAD commands in making 2D drawings. Draw assembled drawings of different types of joints and couplings using
AutoCAD Draw assembled drawings of various types of machine elements using
AutoCAD.
SCHEME OF INSTRUCTION AND EXAMINATIONS
Subject Instruction ExaminationTheory/ Week
Theory /Semester
Practical /Week
Practical /Semester
TotalHour
s
Assessment MarksInternal
BoardExam
Total
12034MachineDrawing -
CAD
2 32 6 96 128 25 75 100
TOPIC AND ALLOCATION
Unit Topic Time (Hrs)I. Section views 6II. Limits, fits and tolerances 10
III. Keys and surface finish 8IV. Screw Threads and fasteners 8V. CAD Drawings 90
Revision and Test 6Total 128 Hrs
UNIT I SECTION VIEWS: 6hrs
Introductions – need for sectioning – Hatching – Inclination of hatching lines –Spacing between hatching lines – Hatching of larger areas – Hatching of adjacentparts – sketch and explanation of full section, Half sections – types, Partial or localsections, Revolved or super unposed sections, Removed sections and offsetsections.
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UNIT II LIMITS, FITS AND TOLERANCES: 10hrs
Introduction – Definition of various terms used in limits – Hole basis system – Shaftbasis system – Types of fits – Selection of fits and applications – types of tolerances– form and position – Indication of tolerances and fits on the drawing.
UNIT III – KEYS AND SURFACE FINISH: 8hrs
Introduction – Types of keys – taper keys – Parallel or feather keys – wood druff keys– Empirical relation between diameter of the shaft and width & thickness of key forthe above types of keys. Definition – Nominal surface – roughness – waviness – lay– productions methods and surface quality – symbol for lay – Indication of surfaceroughness for various machining operations.
UNIT IV SCREW THREADS AND THREADED FASTENERS 8hrs
Introduction – Nomenclature of screw threads – Basic profiles and forms of screwthreads – Left hand and right hand threads – Internal and external threads – Drawingof Vee and square threads – Application of threads – Bolts and Nuts – Drawing ofHexagonal bolt and Nut – Drawing of square head bolts – Riveted head – Types.
UNIT V CAD DRAWINGS
1. Auto cad Theory and Practice 30Hrs2. Sleeve and cotter joint 3Hrs3. . Socket and spigot cotter joint 3Hrs4. Gib and cotter joint 3Hrs5. Knuckle joint 3Hrs6. Flange coupling – protected type 6Hrs7. Universal coupling 6Hrs8. Bushed bearing 6Hrs9. Plummer block 6Hrs10. Swivel bearing 6Hrs11. Simple eccentric 6Hrs12. Machine vice 6Hrs13. Screw Jack 6Hrs
Total 90 Hrs
Auto CAD Theory and Practice :Introduction – open-save-save as-exit-Limits, Units-Line command-Abs coordinateSystem-Relative Polar-Different toolbars in screen-explanationDraw commands-Circle-Arc-Ellipse-Rectangle-Spline-pline-DonutEditing Commands-Array-mirror-break-copy-rotate-chamfer-fillet-move-offset-scale-trim-extend-strecth-plineedit-pedit-xplode.Display commands-Zoom-pan-oops-regen-viewres.Layer – Properties-create Layer-laytrans-matchpropText Command-text-mtext-textedit-mteditDimensioning commands- DimLinear, Dimaligned, Dimradius, Dimdia, Dimangular,Dimbaseline, Dimcontinuous, Dimstyle, DimeditMake BLOCK, Insert block, Divide, Measure, BhatchAttdef, atteditPagesetup, Plot preview, plot
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Revision and Test 6hrs
Text Books:
1. N. D. Bhatt, Machine Drawing, Edn. 37, Charotar Publishing House, Opp.Amul Dairy, Court Road, Anand 388 001, India – 2002.
2. K. R. Goplakrishnan, Engineering Drawing, Dhanalakshmi Publishers,M97-B, 30th Cross Street, 7th Avenue, Besant Nagar, Chennai 600 090.
3. R.C.Parkinson, Engineering Drawing published by English UniversityPress, London – 1986.
Reference Book:
A. C. Parkinsan, A First year Engineering Drawing. First Rep 1982, A.H.Wheeler & Company (P) Ltd., 15, L. B. Shastri Marg, Allaghabed – 211 001.
39
12034 MACHINE DRAWING - CADMODEL QUESTION PAPER
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in PART- C.
PART –A Answer all the questions 1x10=10
1. When half-sectional view is used?2. How is a cutting plane represented in the Orthographic view for obtaining a
full section.3. What is meant by the term Fit?4. Write down the application for transition fit H7/n6.5. Where a wood druff key is used?6. Indicate roughness grade symbol for N10.7. What type of thread is used for transmitting high power?8. Where are multi start thread is used?9. What command is used to constrain the line drawn horizontal and vertical
direction only?10. When do you choose the command PLINE?
PART-B Answer all the questions 3x5=15
11. Explain removed section with suitable sketch.12. When a shaft based system is preferred to hole based system?13. What are the roughness value that can be normally obtained by i) Fine
14. Draw the neat proportionate conventional sketch for a M20 nut15. i) How to begin a new drawing? ii) What are the options available to draw a
circle?
PART-C (20+30)
16. Assemble and draw the orthographic views (Front view and side view/Topview) for the given parts drawing
a) Manual drafting (on the given drawing sheet) (20)b) Using CAD software and print-out (30)
******
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12035 MECHANICS OF MATERIALS AND FLUID MECHANICS LAB
4 Hrs/Week 16 Weeks / SemTotal Hrs : 64
OBJECTIVES: Determine stress strain relations for steel and cast iron. Determine hardness of materials. Perform torsion, bending, impact and shear tests. Determine coefficient of discharge of venture meter and orifice meter. Determine the friction in pipes. Verify Bernoulli’s theorem. Conduct performance test on centrifugal and reciprocating pump. Conduct performance test on impulse and reaction turbine. Design and make fluid power circuits.
Scheme of Instructions and Examinations
Subject Instruction ExaminationHours/wee
kHours/
SemesterAssessment Marks
Internal Board Exam Total
12035 – Mechanics ofMaterials and Fluid
Mechanics lab
4 64 25 75 100
I MECHANICS OF MATERIALS LAB: (2Hrs/Week)
1. Test on Ductile Materials:Finding Young’s Modulus of Elasticity, yield points, percentage elongationand percentage reduction in area, stress strain diagram plotting, tests on mildsteel and cast iron.(Equipment : UTM )
2. Hardness Test:Determination of Rockwell’s Hardness Number for various materials like mildsteel, high carbon steel, brass, copper and aluminium.(Equipment : Rockwell’s Hardness Testing Machine)
3. Torsion test:Torsion test on mild steel – relation between torque and angle of twist-determination of shear modulus-determination of elastic constants for mildsteel.(Equipment : Torsion testing machine)
4. Bending and deflection tests:Determination of Young’s Modulus for steel by deflection test.(Equipment : Deflection testing arrangement )
5. Impact test:Finding the resistance of materials to impact loads by Izod test or Charpy test.(Equipment: Impact testing machine)
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6. Tests on springs of circular section:Determination of modulus of rigidity, strain energy, shear stress by loaddeflection method-Comparison and tension test (Closed coil spring only)(Equipment: Tension testing arrangements)
7. Shear test:Shear test on M.S. bar(Equipment: Shear testing machine)
II FLUID MECHANICS LAB: (2 Hrs/Week)
1. Verifying the Bernoulli’s Theorem(Equipment: The Bernoulli’s Apparatus)
2. Determination of Coefficient of discharge of a Venturimeter (or) Orifice meter.(Equipment: A Centrifugal pump having the discharge line with Venturimeteror Orifice meter arrangement)
3. Determination of the Friction Factor in a Pipe(Equipment: An arrangement to find friction factor)
4. Performance test on a reciprocating pump and draw the characteristic curves.(Equipment: A reciprocating pump with an arrangement for collectingdata to find out the efficiency and plot the characteristic curves)
5. Performance test on a centrifugal pump and draw the characteristic curves.(Equipment: A centrifugal pump with an arrangement for collecting datato find out the efficiency and plot the characteristic curves)
6. Performance test on an impulse turbine(Equipment: An impulse turbine with an arrangement for collecting datato find out the efficiency)
7. Performance test on a reaction turbine(Equipment: A reaction turbine with an arrangement for collecting datato find out the efficiency)
8. Determination of Coefficient of discharge of a small orifice (or) an externalmouthpiece by constant head method.(Equipment: An open tank fitted with a small orifice (or) an externalmouthpiece and a collecting tank with piezometer)
9. Determination of Coefficient of discharge of a small orifice (or) an externalmouthpiece by variable head method.(Equipment: An open tank fitted with a small orifice (or) an externalmouthpiece and a collecting tank with piezometer)
10. Making a suitable Pneumatic (or) Hydraulic circuit connection with DCVS,flow control valve and check valve to show the reciprocating motion of adouble acting cylinder with metering-in control circuit.(Equipment: Either Pneumatic trainer kit with air compressor (or)Hydraulic trainer kit with hydraulic power pack)
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11. Making a suitable Pneumatic (or) Hydraulic circuit connection with DCVS,flow control valve and check valve to show the reciprocating motion of adouble acting cylinder with metering-out control circuit.(Equipment: Either Pneumatic trainer kit with air compressor (or)Hydraulic trainer kit with hydraulic power pack)
SCHEME OF EXAMINATION:
Mechanics of Materials Lab(any one exercise) : 35 marks(1½ Hrs)Fluid Mechanics Lab(any one exercise) : 35 marks(1½ Hrs)Viva - voce : 05 marks
Total : 75 marks
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12036 WORKSHOP – I(SMITHY, FOUNDRY & WELDING)
6 Hrs/Weeks 16 Weeks / SemTotal Hrs : 96
OBJECTIVES: Identify the tools used in foundry. Identify the tools and equipments used in welding. Prepare sand moulds for different patterns. Perform welding operation to make different types of joints. Identify the different welding defects. Appreciate the safety practices used in Smithy and welding. Make components in smithy.
Syllabus:1. Introduction to safety in smithy shop2. Introduction of hand tools and equipments3. Operations in smithy4. Identify the defects in smith forged components
Exercises:1. Round rod to hexagonal rod2. Round rod to square rod3. Round rod to square headed bolt4. Round rod to ‘S’ Shape5. Round rod to flat with 25mm
Material: Dia 12mm X 100mm Length.
2.0 FoundrySyllabus
1. Introduction of tools and equipments2. Types of patterns3. Types of sand4. Preparation of sand moulds5. Furnaces- crucible furnace and tilting furnace6. Melting if non ferrous metal7. Core sands, preparation of cores
44
Exercises:
Preparation of sand mould:1. Solid pattern
a. Stepped Pulleyb. Bearing topc. Gear Wheeld. T-pipe
2. Split patterna. Bent Pipeb. Dumbles
3. Loose Piece Pattern- Dowtail4. Cylindrical core making5. Melting and casting– (Not for Examination, only for class exercises)
3.0 Welding
Syllabus
1. Introduction of safety in welding shop2. Introduction to hand tools and equipments3. Are and gas welding equipments4. Types of joints
Exercises:
1. Arc welding
Lap joint ( Material: 25mm x 3mm Ms Flat ) Butt joint ( Material: 25mm x 6mm Ms Flat ) T-joint ( Material: 25mm x 3mm Ms Flat ) Corner joint ( Material: 25mm x 3mm Ms Flat )
2. Gas Welding
Lap joint ( Material: 25mm x 3mm Ms Flat ) Butt Joint ( Material: 25mm x 6mm Ms Flat )
3. Gas cutting: Profile cutting.4. Spot welding-Lap joint(18/20swg)5. Demonstration of Soldering and brazing
SCHEME OF EXAMINATION:
Foundry : 45 marks (2 hours)Smithy / Welding (by lot) : 25 marks (1 hour)Viva-voce : 05 marks
Total : 75 marks
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12041 APPLIED THERMODYNAMICS
6 Hrs/Week 16 Weeks /Sem.Total Hours : 96
OBJECTIVES:
Explain the basics of systems and laws of thermodynamics, andthermodynamic processes.
Explain different Air cycles. Apply steady flow energy equation for nozzles and condensers. Explain the types and functions of I.C. Engines. Explain the fuels and calorific value of fuels. Explain the performance tests on I.C. Engines. Compare the modes of heat transfer and evaluate the heat transfer by various
modes. Familiarize parts, function and types of Air compressors and determine their
efficiency. Describe the working of Gas turbines.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12041- Applied
ThermodynamicsHours/Week
Hours/Semester Assessment Marks
6 96Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
Unit Topic TIME (Hrs)I. Thermodynamics and Expansion of gases 18II. Steady flow energy equation and Air cycles 18III. Internal combustion engines 18IV. Fuels and Performance of IC Engines 18V. Air Compressors and Gas Turbines 18
Revision and test 6TOTAL 96
UNIT I: THERMODYNAMICS AND EXPANSION OF GASES 18hrs
Introduction - definitions and units of mass, weight, volume, density, specific weightgravity - pressure - units - atmospheric, gauge, vacuum and absolute pressure -temperature - Celsius and absolute temperature - S.T.P and N.T.P conditions - heat -specific heat capacity at constant volume and at constant pressure - work - power -energy - types - thermodynamic system - types -properties and state of system -intensive and extensive properties - thermodynamic process - cycle - point and pathfunction - law of conservation of energy - equilibrium - thermodynamic - zeroth , firstand second law of thermodynamics- problemsPerfect gases - law of perfect gases - Boyle's, Charles', Joule's, Regnault's andAvagadro's law -characteristic gas equation - relation between specific heats and gasconstant - universal gas constant - problems -enthalpy -change in enthalpy - entropy -change in entropy - general equation for change in entropy.
46
Expansion of gases - thermodynamic processes - constant volume, constant pressure,isothermal (hyperbolic), isentropic (reversible adiabatic), polytropic, free expansion andthrotting processes - p-V and T-s diagrams, work done, change in internal energy, heattransfer, change in enthalpy, change in entropy for various processes - problems.
UNIT II: STEADY FLOW ENERGY EQUATION AND AIR CYCLES 18hrs
Steady flow system - control volume - steady flow energy equation - applications- steamboiler - condenser -nozzles - steam and gas turbines -reciprocating and rotarycompressors - non flow energy equation - problems.Air cycles - air standard efficiency - reversible and irreversible processes -thermodynamic reversibility - conditions of reversibility assumptions in deriving airstandard efficiency -Carnot cycle- Otto cycle - Joule cycle -Diesel cycle -comparison ofOtto cycle and Diesel cycle- ideal and actual p-V diagram of Diesel cycles - comparison- problems - dual combustion cycle (description only).
UNIT III: INTERNAL COMBUSTION ENGINES 18hrs
Introduction - classifications -four stroke cycle petrol and diesel engines - merits anddemerits - two stroke cycle petrol and diesel engines - comparison- constructionaldetails of I.C.engine -components of engines - cylinder block, crankcase, cylinder head,liners, oil pan, piston, piston rings, connecting rod, crank shaft, cam shaft, valve andvalve train - material and manufacturing methods - valve timing diagram for four strokepetrol and diesel engines - port timing for four stroke petrol and diesel enginesLayout of fuel supply system in petrol engines - A.C. mechanical fuel pump- simplecarburetor - Solex carburetor - layout of fuel supply system in diesel engine - singleacting fuel feed pump - CAV fuel injection pump -fuel injectors -types of nozzles - fuelfilters.Ignition systems - compression and spark ignition - coil, magneto and electronic ignitionsystems - governing of I.C.engines - quantity and quality governing -cooling systems -air-cooling - water cooling -merits and demerits.Lubrication - purpose - properties of lubricant - types of lubrication system - oil pumpand oil filters -scavenging - super charging- effects and applications - turbo charger.
UNIT IV: FUELS & PERFORMANCE OF I.C ENGINES 18hrs
Fuels - classifications - merits and demerits - requirements of a good fuel - combustionof fuels - stoichiometric air required for complete combustion of fuels- excess air-products of combustion - problems -calorific value - Bomb and Junker’s calorimeter -problems - Orsat apparatus for flue gas analysis - air pollution - effects and control ofpollutionPerformance of I.C engines - Testing - thermodynamic and commercial tests - indicatedpower - brake power - friction power- efficiencies of I.C engines- indicated thermal,brake thermal, mechanical and relative efficiencies - Morse test- procedure - problems -heat balance sheet - problems.
UNIT V: AIR COMPRESSORS AND GAS TURBINES 18hrs
Air compressor - uses of compressed air - classifications of compressor - workingprinciple of a compressor - single stage reciprocating compressor - compressionprocesses - power required to drive the compressor - problems -clearance volume andits effects - volumetric efficiency - power required to drive the compressor withclearance volume -problems- multi stage air compressor - merits and demerits -
47
intercooler - perfect inter cooling - work input on multi stage compressor - condition forminimum work input in multi stage compressor with perfect inter cooling - ratio ofcylinder diameter for minimum work input - problem - rotary compressors - Roots,vane blowers - centrifugal and axial flow air compressors.Gas turbines- classifications - advantages and disadvantages of gas turbines - constantpressure gas turbine - gas turbine with regenerator - inter cooler - reheater - effects -closed cycle gas turbines - merits and demerits of open and closed cycle gas turbine -turbojet engines- merits and demerits - turbo propeller engines- merits and demerits -ramjet- comparison of air - craft and industrial gas turbines.
Revision and Test 6Hrs
Text Books:
1. R.S.Khurmi and J.K..Gupta, Thermal Engineering, Edn. 18,, published byS.Chand & Co.
2. P.K.Nag, Applied Thermodynamics, Edn. 2, Tata McGraw Hill Publishing Co.Ltd., 7, West Patel Nagar, New Delhi 110 008.
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Define temperature2. Define intensive property3. Write the SFEE for a) Steam Boiler b) Steam condenser4. Write the expression for air standard efficiency of Diesel cycle.5. Name the four strokes of a petrol engine6. What is the main function of a carburetor?7. State the difference between indicated power and brake power.8. What for an orsat apparatus is used?9. What is an air compressor?10. What is a gas turbine?
PART- B Answer all the questions 3x5=15
11. Derive an expression for work done during Isothermal process.12. Calculate the air standard efficiency of an Diesel cycle having compression
ratio 18 and expansion ratio 10.13. List out the important properties of a lubricant.14. Explain what is higher calorific value and lower calorific value of a fuel.15. State the effects of a clearance volume in a air compressor.
PART-C Answer any one question from each unit 10x5=5016. 1. 0.25KG of air at a pressure of 140kn/m2 occupies 0.15m3 and from this
conditions it is compressed to 1.4MN/m 2 according to the law pv1.25 = C.Determine (i) Change in Internal energy (ii) Work transfer (iii) Heattransfer iv) Change in Entropy. Assume Cp=1.005kj/jg.k andCv=0.718kj/kg.k. OR (10)
2. Explain open and closed system with atleast two examples each. (10)17. 1. (a) State and explain steady flow energy Equation. (4)
(b) In a steady flow of air through a nozzle, the enthalpy decreases by 40kjbetween two sections. Assuming that there are no other energy changesthan the kinetic energy, determine the increase in velocity at section 2 ifthe velocity at section 1 is 100m/s. (6)
OR2. (a) In an otto cycle the compression ratio is changed from 4.5 to 8.5.
Determine the increase in A.S.E of the cycle. (4)(b) Find the A.S.E of a Diesel cycle engine if the cut off is 6% of the stroke
and the clearance is 1/13th of the stroke take γ = 1.4. (6)18. 1. Explain the neat sketch the working of inline fuel injection pump used in
Diesel Engine. (10)OR
2. Explain the neat sketch the construction and working of water pump coolingsystem. (10)
49
19. 1. With a sketch explain the construction, working and calculation method forfinding out calorific value of a solid fuel using Bomb Calorimeter. (10)
OR2. Explain a) Procedure for Morse Test on a petrol Engine.
b) Procedure of heat balance test on a diesel engine (10)20. 1. Explain with sketches the construction and operation of a) Roots for blower b)
Centrifugal compressor. (10)OR
2. Find the percentage saving in work by compressing air in two stages fromone bar to seven bars instead of in one stage. Assume compression indexas 1.35 in both cases and complete intercooling in two-stage compression.
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Explain the term absolute zero of temperature.2. State the First law of thermodynamics.3. What is meant by control volume.4. Define Air standard efficiency.5. What is meant by valve timing diagram?6. State the different types of cooling systems used in I.C. Engines.7. Write expression for theoretical minimum air required for complete combustion
of 1kg of a fuel.8. Define Mechanical efficiency.9. Name the various types of compression process used in air compression.10. What is an open cycle gas turbine?
PART-B Answer all the questions 1x10=1011.A cylinder contains 3kg of oxygen at 5-bar pressure and temperature of 27ºc.
Determine the volume of the cylinder.12.State the conditions for reversibility.13.Define carburetion and state the requirements of a carburetor.14.What are the requirements of a good fuel?15.Explain with a p-v diagram, the various types of compression.
PART-C Answer any one question from each unit 10x5=5016. 1. 1Kg of air at 11 bar and 80ºc is expanded to 10 times the original volume by i)
Isothermal process ii) Isentropic process. Determine the work done ineach of cases. Also plot these two on a common p-v diagram R=287J/Kg.kand γ=1.4. (10)
OR2. Derive an expression for work done during a polytropic process. (10)
17. 1. a) State the assumptions made in deriving air standard efficiency. (4)b) Derive an expression for A.S.E of an otto cycle. (6)
OR2. What will be the loss of thermal efficiency of a diesel engine with a
compression ratio of 14, if the fuel cut –off is delayed from 5% to 9% of thestroke. (10)
18. 1. Explain with neat sketches the construction and operation of a two strokecycle petrol engine.
(10)OR
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2. Explain with sketches the working of A.C Mechanical fuel pump. (10)
19. 1. The following data were obtained during a trial on an oil engine. Brakepower=73.5kw. Fuel consumed=1kg 16.5kg/hour calorific value offuel=45200Kj/kg. Mechanical efficiency = 82%. Find i) Brake Thermalefficiency ii) indicated Thermal efficiency iii) Indicated power. (10)
0.5%. It is supplied with 50% excess of air. Find i) Minimum mass of airrequired for complete combustion of 1kg of fuel ii) Gravimetriccomposition of the products of combustion. (10)
20. 1. a) Explain the working of a multistage air compression with intercooling.(4)
b) Derive an expression for workdone by a two stage reciprocating aircompressor with complete inter cooling. (6)
OR2. Explain with a neat sketch the working of a ramjet. State its applications and
advantages. (10)
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12042 MACHINE SHOP TECHNOLOGY
6 Hrs/Week 16 Weeks /Sem.Total Hrs : 96
OBJECTIVES: Explain the working of machine tools planer, shaper and slotter. Compare various work holding devices Explain the working of machine tools drilling machine and milling machine. Distinguish various types of milling cutter. Classify the different types of grinders and grinding wheels. Explain the broaching operation and boring operation and their applications. Explain the milling procedure for spur, helical and bevel gears. Explain the various types of gear generating processes Compare the various types of jigs and fixtures. Explain the different types of press working operations. Appreciate the use of non-conventional machining processes.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12042- Machine
ShopTechnology
Hours/Week Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
Unit Topic TIME (Hrs)I. Planer, Shaper and Slotter 18II. Drilling Machines and Milling Machines 18
III. Grinding, Broaching, Boring and Jig Boring 18IV. Gear manufacturing Practice – Forming and
Generating18
V. Jigs & Fixtures, Press working & Non-Conventional Machining process.
18
Revision and test 6TOTAL 96
UNIT-I: PLANER, SHAPER AND SLOTTER 18 Hrs
Planer: Types of planers-description of double housing planer-specifications-principles of operation-drives-quick return mechanism-feed mechanism- work holdingdevices and special fixtures-types of tools-various operation.Shaper: Types of shapes-specifications-standard-plain-universal-principles ofoperations-drives-quick return mechanism-crank and slotted link-feed mechanism-work holding devices-Special fixture-various operations.Slotter: Types of slotters-specifications-method of operation-Whitworth quick returnmechanism-feed mechanism-work holding devices-types of tools.
53
UNIT -II: DRILLING MACHINES AND MILLING MACHINES 18 Hrs
Drilling machines: Drills-flat drills-twist drills-nomenclature-types of drillingmachines-bench type-floor type-radial type-gang drill-multispindle type-principle ofoperation in drilling-speeds and feeds for various materials-drilling holes-methods ofholding drill bit-drill chucks-socket and sleeve-drilling-operation-reaming-countersinking-counter boring-spot facing-tapping-deep hole drilling.Milling machines: Types-column and knee type-plain-universal milling machine-vertical milling machine-specification of milling machines-principles of operation-workand tool holding devices-arbor-stub arbor-spring collet-adapter-milling cutters-cylindrical milling cutter-slitting cutter-side milling cutter-angle milling cutter-T-slotmilling cutter-woodruff milling cutter-fly cutter-nomenclature of cylindrical millingcutter-milling process-conventional milling-climb milling-milling operations-straddlemilling-gang milling-vertical milling attachment.
UNIT-III: GRINDING, BROACHING, BORING AND JIG BORING 18 Hrs
Grinding machines: Types and classification-specifications-rough grinding –pedestal grinders- portable grinders- belt grinders-precision grinding-cylindricalgrinder-center, centerless type – surface grinder-planetory grinders-principles ofoperations-grinding wheels-abrasives-natural and artificial diamond wheels-types ofbonds-grit, grade and structure of wheels-wheels shapes and sizes-standard markingsystems of grinding wheels-selection of grinding wheel-mounting of grinding wheels-Dressing and Truing of wheels-Balancing of grinding wheels.Broaching: Types of broaching machine-horizontal vertical and continuousbroaching-principles of operation-types of broaches-classification-broach toolnomenclature-broaching operations-simple examples.Boring and Jig boring: Boring machines-horizontal and vertical types-fine boringmachines-boring tools-jig boring machine-measuring system-hole location procedure-deep hole boring.
UNIT-IV: GEAR MANUFACTURING PRACTICE – FORMING ANDGENERATING 18 Hrs
Gear manufacturing practice-Forming and Generating processes:Gear forming process in milling-dividing head-principles of operation-indexing-linearindexing-simple-differential and angular indexing-problems-gear milling, cutterselection-module-pressure angle-milling procedure for spur, helical and bevel gears-problems.Generating process-gear shaper-gear hobbing-principle of operation only-gearfinishing processes-burnishing-shaving-grinding and lapping-gear materials-cast iron,steel, alloy steels, brass, bronze, aluminium, nylon.
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UNIT-V: JIGS & FIXTURES, PRESS WORKING & NON-CONVENTIONALMACHINING PROCESS 18 Hrs
Jigs and Fixtures: Definitions and concept of Jig and fixture-Advantages of jigs andfixtures-elements of jigs and fixtures-locating devices-'V' locators-fixed stop locators-adjustable stop locators-clamping devices-strap clamp, screw clamp-cam actionclamp-types of jigs-box drill jig-indexing drill jig-types of fixtures-keyway millingfixture-string milling fixture.Press working: Types of presses-mechanical and hydraulic presses-press tools andaccessories-press working operations-bending operations-angle bending-channelbending -curling-Drawing-shearing operations - blanking, piercing trimming-notching-lancing-shaving-parting off.Non-Conventional Machining process: Construction and working of Ultrasonicmachining-chemical machining-electro chemical grinding-electrical dischargemachining-plasma arc machining-LASER machining-Advantages – Disadvantages-Applications-of the above processes.
Revision and Test 6Hrs
Text Books:1. Hajra Choudry & Battacharya, Elements of Workshop Technology-Vol. I & II, Edn.
11, published by Media Promoters and Publishers Pvt. Ltd., Seervai Buildings `B’,20-G, Noshir Bharucha Marg, Mumbai 400 007 - 2007
2. Jain & Gupta, Production Technology, Khanna Publishers, 2-B, North Market,Naisarak, new Delhi – 110 006 – 2006.
Refenence Books:1. HMT, Production Technology, Edn. 18, published by Tata McGraw Hill Publishing
Co. Ltd., 7, West Patel Nagar, New Delhi 110 008.2. Myro N Begman, Manufacturing process, Edn. 5, Tata McGraw Hill Publishing Co.
Ltd., 7, West Patel Nagar, New Delhi 110 008.3. WAJ. Chapman, Workshop Tech Vol I,II, III, published by Viva Books Pvt. Ltd.,
4262/3, Ansari Road, Daryaganj, New Delhi 110 002.4. NITTTR, Production processes published by . 5, Tata McGraw Hill Publishing Co.
Ltd., 7, West Patel Nagar, New Delhi 110 008.
55
12042 MACHINE SHOP TECHNOLOGYMODEL QUESTION PAPER – I
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=101. What are different drive mechanism used to drive the table of a planer?2. What are types of slotting machines used in the Industry?3. Define the depth of a drilling operations.4. Differentiate between plain milling machine and universal milling machine.5. What is grit in a grinding wheel manufacturing?6. What are types of boring machine?7. What is pressure angle of a gear?8. What are the different types of Indexing?9. Define fixture.10. What is plasma?
PART-B Answer all the questions 3x5=1511. Explain with a neat sketch machining of angular surface in a Shaper.12. What are the specifications of a milling machine?13. Explain with a neat sketch the mounting of a grinding wheel.14. Write the step by step procedure for manufacturing of spur gear in a milling
machine.15. Differentiate between the blanking tool and piercing tool.
PART-C Answer any one question from each unit10x5=50
16. 1. a) Explain with a neat sketch the slotted link quick return mechanism of ashaper. (5)
b) What are the different operation performed on a slotter? Explain with aneat sketch any one such operation. (5)
OR2. a) Explain with a neat sketch the automatic feed mechanism of a planer.
(6)b) What are specifications of a shaper? (4)
17. 1. a) Nomenclature of a twist drill. (5)b) Explain with a neat sketch the ‘T’ – slot milling operation. (5)
OR2. a) List out the drilling operations. Explain with a neat sketch any two such
operations. (6)b) Explain with a neat sketch the arbor of a milling machine. (4)
18. 1. a) BIS marking of a grinding wheel – explain? (6)b) Explain with a neat sketch the Jig boring machine. (4)
OR2. a) Sketch the horizontal boring machine and label the parts. (5)
b) Explain with a neat sketch the planetary grinding operations. (5)
56
19. 1. a) Explain with a neat sketch the differential Indexing method. (4)b) Explain with a neat sketch the gear hobbing Process. Write its
advantages. (6)OR
2. a) What are different methods of gear finishing processes? Explain any twoProcess? (6)
b) What are the merits and demerits of nylon as gear material?(4)
20. 1. a) Explain with a neat sketch the box drill jig.(4)
b) Write short notes on: (i) Bending(ii) Lancing(iii)Shaving (6)
OR2. Explain with a neat sketch the electrical discharge machining processes.
What are merits and demerits of this processes. (10)
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. What is the function of a clapper box in a shaper?2. What is quick return mechanism of slotter?3. What are the different types of drilling machine?4. What are the different tool holding devices used in a milling machine?5. List out the boring tools.6. What are the different types of broaching machine?7. What is the amount of crank movement for manufacturing 20 Teeth gear ona milling machine.8. What are the advantages of aluminum as a gear material?9. Define Jig.10. What is Press tool?
PART – B Answer all the questions 5X3=15
11. What are the specifications of a Planer?12. Differentiate between the gang milling and struddle milling operations.13. What are the different feeds used in centreless?14. List out the gear finishing processes. Explain any one gear finishingprocesses.15. What are the advantages of Electrical discharge machining?
PART – C Answer any one question from each unit 5X10=50
16. 1. a) Sketch a double housing planer and label the principal parts of a planer.(5)
b) Explain with a neat sketch the whit worth quick return mechanism of aslotter. (5)
OR2. a) Explain with a neat sketch the automatic feed mechanism of a shaper.
(5)b) List out the work holding devices used in a planer. Explain with a neat
sketch any one such device. (5)
17. 1. List out the drilling operations. Explain with a neat sketch any fouroperations. (10)
OR2. a) Nomenclature of a cylindrical milling cutter. (5)
b) Explain with a neat sketch the milling processes. (5)
18. 1. a) Explain with a neat sketch the cylindrical grinding machine. (5)b) Nomenclature of a pull broach (5)
OR2. a) What are the criteria while selecting a grinding wheel? (5)
58
b) List out the different methods of locating a hole in jig boring machine.Explain any one method? (5)
19. 1. a) Explain with a neat sketch the gear shaper. Write its demerits. (6)b) Explain with a neat sketch the simple indexing method (4)
OR3. a) Write the step by step procedure for manufacturing of bevel gear in a
milling machine. (5)a) What are the different materials used for manufacturing of gears? Write
its advantages. (5)20. 1. a) What is locating elements? Explain with neat sketch any two locators.
(5)b) Explain with a neat sketch the ultrasonic machining process. (5)
OR2. Explain with a neat sketch the different drive mechanism used in a presses.
(10)
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12043 ELECTRICAL AND ELECTRONICS ENGINEERING
5 Hrs/Week 16 Weeks /Sem.Total Hrs : 80
OBJECTIVES:
Define Voltage, Current, Resistance, Power and energy. State Ohm's law, Kirchoff's law and Faraday's laws of electromagnetic
induction. Explain the fundamentals of alternating current. Describe the construction and working of DC machines. Describe the construction and working of transformer and alternator. Explain the working of various types of AC motors. Describe the construction and working of stepper motor. Appreciate the use of safety practices in electrical safety. State the characteristics of semiconductor diode. Explain the construction and working of PNP and NPN transistor. Explain the principle and working of thyristors. State the features and benefits of PLC. Compare PLC circuits and hardware circuits. Design ladder logic for operating motors.
IIDC Generator, DC Motor, Transformer andAlternator
15
III AC Motors and Electrical Safety 15IV Basic Electronics and logic gates 15V Programmable Logic Controller 15
Revision and Test 5TOTAL 80
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UNIT I – DC AND AC CIRCUITS AND BATTERIES 15 HRS.
Definitions – Electric current, voltage and resistance – Ohm’s Law and Kirchoff’sLaws – Resistance in series, parallel and series parallel – Simple problems –Electromagnetism (Definitions only), Magnetic flux, Flux density, Magnetic fieldIntensity, MMF, permeability, reluctance, Faraday’s laws of electro magneticInduction.Fundamentals of AC voltage and current – Peak, average, RMS value of sine wave,Frequency, time period, amplitude, power, power factor (Definition only) Ac circuitsRLC in series star, Delta Connections - relationship between phase and linevoltages, current in star and Delta connections.Batteries – classification of cells – construction of ni – iron and cadmium cell conceptof recharging cells – lead acid cell – construction - indication of full charged cellsdefects, and remedies, applications.
UNIT II – DC GENERATOR, DC MOTOR, TRANSFORMER AND ALTERNATOR15 HRS.
DC Generator Construction – Principles of operation, types and applications.DC Motor construction – Principles of operation, types and applications.Necessity for starter – three point, four point starter.Transformer – principle of operation and construction EMF equation – losses in atransformer – efficiency – autotransformer – three phase transformer – applications.Alternator construction – principle of operation – types and applications.
UNIT III – AC MOTORS AND ELECTRICAL SAFETY 15 HRS.
AC motors: Principle of operation of single phase capacitor start induction motor –applications – three phase induction motors – squirrel cage and slip ring IM(construction and working principle only) – applications – speed control of threephase induction motor – necessity of starter – DOL and star delta starter.Special motor: PMDC, Stepper motor – construction, working principle andapplication.Electrical Safety – importance of earthing – electric shock – first aid for electric shock– precautions against shock – cause of accidents and their preventive measures –energy conservation.
UNIT IV – BASIC ELECTRONICS AND LOGIC GATES 15 HRS.
Semiconductor materials – N type and P type – PN Junction – forward and reversebias, characteristics of PN functions diode – Half wave rectifier, full wave rectifier,bridge rectifier, zener diode and avalanche break down, characteristics of zenerdiode – application of zener diode.Transistor – construction of NPN and PNP types – basic bias requirements (commonemitter configuration only)Thyristors – principle and working of SCR – characteristics – applications.Introduction of integrated circuits – classification and packages only – applications.Logic Gates – positive and negative logic, definition, symbol, truth table, Booleanexpression for OR, AND, NOT, NOR, NAND, EXOR and EXNOR gates.
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UNIT V – PROGRAMMABLE LOGIC CONTROLLER 15 HRS.
PLC definition – features and benefits of PLC – Systems and its elements – input andoutput elements – PLC memory system – PLC circuit verses hard wired circuits –sensors – types of sensors – limit switch, reed switch, photo electric sensor, inductiveproximity sensor – types of contacts normally open (NO) contact, normally closed(NC) contract – ladder logic symbol – AND logic OR logic , truth table – stepsinvolved in application circuits using a PLC – PLC scan input Programme scan andoutput scan – design ladder diagram for operation of motor using AND and OR logic.Design ladder logic diagram for ON delay control of a motor and OFF delay control of
a motor.
Revision and Test 5 Hrs
Text Books:
1. B.L. Theraja, Fundamentals of Electrical and Electronics Engineering, S.Chand &Co.
2. T. Thiyagarajan, Fundamentals of Electrical and Electronics Engineering, ScitechPublicatiuons (India) Pvt.ltd.
Reference Books:1. Mikell P. Groover, Automation, Production System and Computer Integrated
Manufacturing, Edn. 2 published by Pearson Education (Singapore) Pte. Ltd.,Indian Branch, 2842 F.I.E., Patparganj, Delhi 110 002, India.
2. KB Raina & S.K.Battachariya, Electrical Design Estimating and Costing, Edn. 6,Tata McGraw Hill Publishing Co., 7, West Patel Nagar, New Delhi 110 008.
3. Gary Dummy, Introduction to Programmable logic controls, Thomson Debnarlearning second edition second reprint 2003.
4. B.L.Theraja & A.K. Theraja, Electrical Technology Vol. I & II, Edn. 23, publishedby S.Chand & Co. Ltd., Ram Nagar, New Delhi 110 055.
62
12043 ELECTRICAL AND ELECTRONICS ENGINEERING
MODEL QUESTION PAPER – I
DURATION : 3 HRS.MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Define Electrical power? Write its unit.2. Define flux density?3. Write any two applications of transformer.4. What is the necessity of starter?5. What are the types of three phase induction motors?6. How will you avoid Electrical shock. Any two precautionary measure?7. Mention any two types of P type Semi conducting material.8. Draw the symbols for the following logic gates. 1.AND 2.EXOR9. Write any two benefits of PLC.10. Draw the ladder diagram for obtaining the OR logic.
PART –B Answer all the questions 3x5=15
11. When two resistors are connected in series the effective resistance is 10ohms and when they are connected in parallel the effective resistance is 2ohms. Find the value of two resistors.
12. Write the principle of operation of DC motor.13. Write the types of single phase induction motors and write any two application
for each.14. Draw the basic circuit of half wave rectifier using diode and write its principle
of operation.15. Develop the ladder diagram for on delay timer and write its truth table.
PART –C Answer any one question from each unit10x5=50
15. 1. a) Find the effective resistance for the following circuit and powerdeveloped (6)
5Ω 3Ω
2Ω50V
b) What are the applications of lead acid cell (4)OR
2. a) State and explain Kirchoff’s law. (4)
63
b) Find the current flowing through 5 ohms resistor using Kirchoff’s laws.(6)
2Ω 10Ω
5Ω 15V20V
16. 1. Explain the constructional features of Altenator with suitable diagram(10)
OR2. Explain the principle of operation of single phase transformer. What are its
Losses and derive the emf equation of single phase transformer.(10)
18. 1. a) Draw three point starter for DC machine. (6)b) Write the working principle of stepper motor. (4)
OR2. a) Write the working principle of three phase Squirrel cage induction
motor. (6)b) Write any four applications of single phase induction motors (4)
19. 1. Draw the basic diagram for common emitter configuration with properbiasing and explain.
(10)OR
2. Write the principle and working of SCR along with its characteristic(10)
20. 1. a) Compare PLC circuit with hard wired circuit (6)b) Develop a ladder diagram for starting a three phase induction motor
using DOL starter using PLC. (4)OR
2. a) Design a ladder diagram for off delay control of a motor using PLC (6)b) What are the different types of sensors used in automation industry
using PLC (4)
64
12043 ELECTRICAL AND ELECTRONICS ENGINEERINGMODEL QUESTION PAPER – II
DURATION : 3 HRS. MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Define mmf.2. What is the relationship between line voltage and phase voltage and linecurrent and phase current in
star and delta connected system.3. Explain the principle of operation of DC generator.4. Mention any two application of DC motor.5. Write the types of single phase induction motors.6. What is the first aid you will give when a person is affected by shock?7. Classify Integrated circuits.8. Draw the symbols for the following 1. Semiconductor diode 2. Zener diode9. Define PLC.10. Draw the ladder diagram to obtain AND logic using PLC.
PART –B Answer all the questions 3x5=15
11. What are the indications of fully charged cell?12. Explain the principle of operation of single phase transformer.13. What is the importance of earthing? Write any three types.14. Draw the circuit of full wave bridge and its operation with suitable waveforms.15. Design and develop the ladder diagram for ON delay timer using PLC.
PART –C Answer any one question from each unit10x5=50
16. 1. a) Define faraday’s laws of Electro magnetic induction (4)b) Determine the value of R if the voltage across it is 25 volts (6)
20Ω
100V 50ΩR
2. a) Draw the constructional features of lead acid battery. (4)b) Find the value of current flowing through 3Ω for the following circuit. (6)
5Ω 2Ω
3Ω 10V20V
65
17. 1. Explain the constructional features of DC machine with suitable diagram.(10)
OR2. Draw the circuit of four point starter and write in detail about its operation.
(10)
18 1. Write in detail how will you control the speed of three phase inductionmotor. (10)
OR2. Write the principle of operation of single phase capacitor srart induction
motor with suitable sketch. (10)
19 1. a) Explain avalanche break down and zener break down (4)b) Draw the characteristics and applications of zener diode also write how
it can be used as a stabilizer (6)OR
2. a) Explain what is mean by positive and negative logic (4)b) Draw the symbol and truth table for the following logic gates
1. NOT 2. OR 3. AND 4. NAND 5. EXOR 6. EXNOR (6)
20 1. a) What is input and output scan regarding PLC operation (4)b) Develop the ladder diagram for OFF delay timer control of motor using
PLC. (6)OR
3. a)Design and develop ladder logic for semi automatic starter for starting ofthree phase induction motor using PLC (6)
b) What are the different types of contactors used in automation industryusing PLC (4)
66
12044 THERMODYANAMICS LABORATORY
6 Hrs/Week 16 Weeks /Sem.Total Hrs : 96
OBJECTIVES:
Determine the flash point, power point and viscosity of oil. Identify the parts of petrol engine and their functions. Identify the parts of diesel engine and their functions. Draw the Valve timing diagram of petrol Engine. Draw the port timing diagram of two stroke petrol engine. Conduct performance test on petrol engines. Conduct performance test on diesel engines. Identify the parts of a high pressure boiler and their applications. Prepare heat balance sheet for an I.C. Engine.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12044-
Thermodynamics Laboratory
Hours/Week Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
Study Exercise: (Not for Examination)
1. Study of petrol engine & diesel engine and its components.2. Study of high-pressure boiler (with model).3. Study of boiler mountings.4. Study of boiler accessories.
List of experiments
PART A
1. Determining flash and fire points of the given oil using open cup apparatus.2. Determining flash and fire points of the given oil using close cup apparatus.3. Determining the absolute viscosity of the given lubricating oil using Redwood
viscometer.4. Determining the absolute viscosity of the given lubricating oil using Saybolt
viscometer.5. Valve timing diagram of four-stroke cycle petrol engine.6. Valve timing diagram of four-stroke cycle diesel engine.7. Port timing diagram of two-stroke cycle petrol engine.
PART B
1. Load test (Performance Test) on petrol engine.2. Load test (Performance Test) on diesel engine.3. Morse test on multicylinder petrol engine.4. Heat balance sheet on I.C engine.5. Emission test for petrol / diesel engine.6. Volumetric efficiency of air compressor.
67
SCHEME OF EXAMINATION:
One question from PART A : 25 marks (1 hour)One question from PART B : 45 marks (2 hours)Viva voce : 05 marks
Total : 75 marks
68
12045 ELECTRICAL AND ELECTRONICS ENGINEERING LABORATORY
6 Hours / Week 16 Weeks/Sem.
Total Hours : 96 Hrs.
SCHEME OF INSTRUCTION AND EXAMINATION
Subjects Instructions Examinations12045- Electrical and
Electronics EngineeringLaboratory
Hours/Week
Hours/Semesters
Internal BoardExam
Total
6 96 25 75 100
OBJECTIVES:
Verify Ohm's law. Estimate power and power factor in single phase circuit. Determine the efficiency of single phase transformer. Find the efficiency of DC shunt motor and induction motors. Determine the VI characteristics of PN diode and SCR. Construction and testing of half wave and full wave rectifier. Use bridge rectifiers to convert AC into DC. Verify the different logic gates AND, OR, NOT, NOR, NAND, EXOR, EXNOR.
LIST OF EXPERIMENTS :
ELECTRICAL:
1. Verification of Ohm’s Law.2. Measurement of power and power factor in single phase circuit.3. Open circuit and short circuit test on a single phase transformer to find thelosses and efficiency.4. Starting a three-phase induction motor by DOL starter and noting the no loadcurrent and speed.5. Load test on DC shunt motor to find the efficiency.6. Load test on a three-phase induction motor at various loads to find theefficiency.7. Starting a three phase induction motor by Star / Delta starter and noting the noload current and speed.8. Load Test Single-Phase transformer.
ELECTRONICS:
9. VI Characteristics of a PN Junction diode.10. VI Characteristics of a SCR.11. Construct a Half wave Rectifier without filter and measure AC input and DCoutput voltage.12. Construct a Full wave rectifier without filter and measure AC input and DCoutput voltage.13. Construct a bridge Rectifier with filter and measure AC input and DC outputvoltage.14. Verification of truth table for AND, OR, NOT, NOR, NAND, EXOR and EXNORgates.
69
SCHEME OF EXAMINATION:
Electrical Experiment : 35 marks (1½ Hrs)Electronics Experiment : 35 marks (1½ Hrs)Viva-Voce : 05 marks
Total : 75
70
12046 WORK SHOP-II(Turning, Drilling, Shaping)
6 Hrs/Week 16 Weeks /Sem.
Total Hrs : 96
OBJECTIVES:
Identify the parts of a center lathe, drilling machine & shaping machine andtheir functions.
Use tools and instruments for turning, drilling and shaping. Identify the work holding devices Hold the work in proper work holding devices. Set the tools for various operations. Operate the lathe, drilling machine & shaping machine Machine a component using lathe, drilling machine & shaping machine. Follow safety practices while machining.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction ExaminationsHours/Week
Hours/Semester Assessment Marks
12046- Workshop –II
(Turning, Drilling &Shaping)
6 96
Internal Board Exam Total
25 75 100
LATHE, DRILLING & SHAPING MACHINES
Syllabus:
1. Introduction of safety in operating machines.2. Introduction to lathe, drilling machine & shaping machine and its parts.3. Introduction to work holding devices and tool holding devices.4. Types of tools used in lathe work, drilling & shaping.5. Types of measuring instruments and their uses.6. Setting of work and tools.7. Operation of lathe, drilling & shaping.8. Practice on a lathe, drilling and shaping machine
Note: The dimensions may be modified according to the materials specified.
Enclosure: Sketches of Lathe, drilling & shaping Exercises.
71
Scheme Of Examination:
Lathe exercise : 45 marks (2 hours)Shaping / Drilling by lot : 25 marks (1 hour)
Viva-Voce : 05 marks
Total : 75 marks
LATHE
72
73
DRILLING
74
75
SHAPING
76
77
78
12051 DESIGN OF MACHINE ELEMENTS
7 Hrs/Week 16 Weeks / Sem.Total Hrs : 112
OBJECTIVES: Select Engineering materials for specific applications. Explain the design consideration of machine parts. Design shafts, keys and couplings for power transmission. Compare the different types of couplings. Design belts and pulleys for power transmission. Differentiate the various types of bearings and their applications. Design gears for power transmission. Design hand lever, foot lever and crank lever
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction ExaminationHours/week Hours/Semester Assessment Marks
Internal Board Exam Total12051 – Design
of MachineElements
7 112 25 75 100
TOPICS AND ALLOCATION
UNIT TOPIC TIME ( Hours )I. Selection of Materials, Procedure for design, Design of
Shaft21
II. Design of bolt, Pins, KeysDesign of cotter joint and couplings
21
III. Design of Belts 21IV. Design of Bearings 21V. Design of Levers
Design of Gears21
Revision and Test 7Total 112
UNIT – I SELECTION OF MATERIALS, PROCEDURE FOR DESIGN, DESIGN OFSHAFT 21 Hrs
Factors affecting selection of materials – Ferrous metals – Cast Iron, wrought Iron,Steel, alloy steel-BIS Specification of Engineering material- Non – ferrous metals –copper, alloys of copper, Aluminium – alloys of aluminium, Tin, Zinc- Procedure fordesigning machine elements – Types of failures.Design of Shafts:Forces on the shaft due to belt and gear drives – Maximum bending moment –Maximum Torque – Determination of shaft size based on combined bending andtwisting moments – Problems.
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UNIT – II DESIGN OF BOLT, PINS, KEYS DESIGN OF COTTER JOINT ANDCOUPLINGS 21 Hrs.
Design of bolts, Pins and keys: Bolt – Stud – Nut – Design of bolted joints –Design of cylinder cover studs – Taper pins – Type of keys – sunk keys – Featherkeys –spline shafts – Design of sunk key – Effect of Key ways -Problems.Design of Cotter Joint and Couplings: Design of – Sleeve and cotter joint – socketand spigot joint – rigid flange couplings – Problems.
UNIT – III DESIGN OF BELTS 21 Hrs.
Design of Flat belts: Type of belts – materials for belts – Designation of belts – Beltdrives – Slip –power transmitted by belt – centrifugal tension-condition for maximumpower transmission-initial tension (No derivation) Problem - Design procedure for flatbelts – Design of flat belt based on Manufacturer’s data – Problem.
Design of V-belts: V-belt drives – power transmitted (Problem)– power Design of V-belt drives – Selection of V-belt by using Manufacturer’s data – Problems.
UNIT – IV DESIGN OF BEARINGS 21 Hrs.
Design of Bearing: Types of bearing – Ball bearing – Radial and thrust ball bearing– Single row – Double row – Self aligning bearings – Roller bearings – Cylindrical,Spherical, Needle and taper – Standard dimensions and designation of bearings –Materials used for ball and roller bearings – Lubrication of bearings – Journal bearing– Heat generated – Heat dissipated – Design procedure for journal bearings –Problems (Design questions based on approved data book only)
UNIT – V DESIGN OF LEVERS DESIGN OF GEARS 21 Hrs.
Design of Levers: Type of levers – Application – Design of hand lever – Foot lever –Cranked lever – Problems.Design of Gears: Type of Gears – Gear materials – Spur gear terminology – Geardesign by Lewis and Buckingham Equation – Design procedure for spur gear basedon Lewis and Buckingham equation – Problems (Based on approved data book only)- Speed reducer.
3. Design Data Book, by PSG College of Technology, Revised Edn. 1978 publishedby Kalaikathir Achagam, Kalakathir Buildings, 670 Avinasi Road, Coimbatore 641037 – 2004.
4. Design Data Book, Bala Chitra Publishers, Revised Edn. 2003, published byBalachitra Publication, Coimbatore – 2.
Reference1. R. S. Khurmi & J. K. Gupta, A text book of machine design, Edn. 18, EurosiaPublishing House Pvt. Ltd., Ram Nagar, New Delhi 110 055 – 2006.
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12051 DESIGN OF MACHINE ELEMENTSMODEL QUESTION PAPER - I
DURATION : 3 HRS. MAX MARKS:75NOTE: Answer all the questions by either or choice.
Each question carries 15 marks.Approved Data book, P.S.G Data book may bepermitted.
1. a) What are the effects of alloying elements on steel? (5)b) A mild steel rod supports a tensile load of 50KNand the stress in the rod is
limited to 100N/mm2. Determine the size of the rod when the cross section isi) circular ii) square and iii) rectangular with width = 3 x t.
OR (10)A shaft is supported on bearings A and B 800 mm between centres. A 20straight tooth spur gear with 600 mm pitch diameter is located 200mm to theright of left hand bearing A and a 700 mm diameter pulley is mounted 250 mmtowards the left of bearing B. The gear is driven by a pinion with a downwardtangential force while the pulley drives the horizontal belt having 180angle ofwrap. The pulley also serves as a flywheel and weighs 2000N. The maximumbelt tension is 3:1. Determine the maximum bending moment and the necessaryshaft diameter if the allowable shear stress of the material is 40N/mm2.
(15)
2. A steam engine cylinder has an effective diameter of 350mm and the maximumSteam pressure acting on the cylinder cover is 1.25N/mm2, Calculate thenumber and the size of studs required to fix the cylinder cover. Assuming thepermissible Stress in the studs as 33MPa. (15)
ORDesign a sleeve and cotter joint to withstand a tensile load of 70KN. All parts ofthe joint are made of the same material and the permissible stresses are as intension 56 N/mm2 , in compression 135 N/mm2 and in shear is 62 N/mm2
(15)
3. a) List the types of belts and the material used for it. (5)b) Design a belt drive to transmit 22.5KW at 740r.p.m. to an aluminium rolling
machine. The speed ratio is 3. The distance between the pulleys is 3m.Diameter of the rolling machine pulley is 1.2m.
OR (10)a) Design a V-belt drive and calculate the actual belt tensions and average
stress from the following data: diameter of driven pulley is 500mm, diameterof driving pulley is 150mm, centre distance between pulleys is 925mm, speedof the driven pulley is 300r.p.m., speed of the driving pulley is 1000r.p.m.power transmitted is 7.5KW. (15)
4 a) With a neat sketch explain rolling contact bearing. (5)b) A full journal bearing has the following specifications: Journal diameter is 60
mm, bearing length is 75mm, radial load on the bearing is 25KN, radialclearance is 0.06mm, speed of the rotation is 1450r.p.m. Determine the meanviscosity of the lubricating oil ,if the minimum film thickness under theoperating condition is 0.0125mm. (10)
ORa) Explain the significance of the bearing characteristics number (5)b) Design a journal bearing for a centrifugal pump from the following data: Load
on the journal is 20KN, Speed of the journal is 900p.m., Type of the Oil used
81
is SAE 10 for which the absolute viscosity at 55C is 17Cp, AmbientTemperature of the oil is 15.5C, Maximum bearing pressure for the pump is1.5N/mm2, Heat dissipation co-efficient is 1232J/s/m2/C. Calculate also massof lubricating oil required for artificial cooling , if rise of temperature of oil islimited to 10oC. (10)
5. a) A gear drive is required to transmit a maximum power of 25KW. The velocityratio is 1:2 and r.p.m. of the pinion is 200. The approximate centre distancebetween the shafts may be taken as 600mm. The teeth has 20 stub involuteprofiles. The material used for the gear is C.I. Find the module, face width andnumber of teeth on each gear. Check your design for dynamic and wearloads. (15)
ORa) A foot lever is 1m from the centre of the shaft to the point of application of the
load of 750N. The allowable tensile stress is 75N/mm2 and the allowableshear stress is 70N/mm2. Determine 1) diameter of shaft 2)dimensions of boss 3) diameter of shaft at the centre of the bearing4) dimensions of key 5) dimensions of rectangular arm of the foot lever fromthe centre of the Shaft, assuming the width of the arm is 3 times thethickness. (15)
82
12051 DESIGN OF MACHINE ELEMENTSMODEL QUESTION PAPER - II
DURATION : 3 HRS. MAX MARKS:75NOTE: Answer all the questions by either or choice.
Each question carries 15 marks.Approved Data book, P.S.G Data book may be permitted.
1. a) State the purpose of alloying (5)b) A pull of 100KN is transmitted from one shaft to another shaft through a pin
by a knuckle joint. If the maximum permissible tensile stress in the shaft is100 N/mm2 and the permissible shear stress in the pin is 80 N/mm2. Findthe diameter of the shaft and of the pin. (10)
ORa) A pair of wheels of a railway wagon carries a load of 50KN on each axle
box, acting at a distance of 100mm outside the wheel base. The gauge ofthe rails is 1.4m. Find the diameter of the axle between the wheels, if thepermissible stress is 100N/mm2. (10)
b) How the free cutting steel is designated?(5)
2. a) Design a sleeve and cotter joint to withstand a tensile load of 60KN. Allparts of the joint are made of the same material and the permissiblestresses are as in tension 60 N/mm2 , in compression 125 N/mm2 and inshear is 70 N/mm2 . (15)
ORa) Design a protected type cast iron flange coupling for a steel shaft
transmitting 15KW at 200 rpm and having an allowable shear stress of 40MPa. The working stress in the bolt should not exceed 30MPa. Assume thatthe same material is used for shaft and key and that the crushing stress istwice the value of its shear stress. The maximum torque is 25% greaterthan the full load torque. The shear stress is for cast iron is 14MPa.
(15)3. a) Compare V-belt with flat belt.
(5)b) A power of 60KW at 750 rpm is to be transmitted from an electric motor to a
Compressor shaft at 300rpm by V-belt. The approximate larger pulleydiameter Is 1500mm. The approximate centre distance is 1650mm, crosssectional area is 350 mm2 , and density is 1000kg/m3 , having an allowabletensile stress of 2 MPa is available for use. Overload factor is 1.5, = 34, = 0.28. Design the belt drive. OR
(10)a) A leather belt drive transmits 15KW power. The centre distance between
the pulleys is twice the diameter of the big pulley. The speed of big andsmall pulleys are 480r.p.m. and 1440r.p.m. respectively. The belt shouldoperate at a velocity of 20m/s approximately and the stresses in the beltshould not exceed 2.25 N/mm2 , the density of the leather is 0.95gm/cc andthe co-efficient of friction is 0.35. The thickness if the belt is 5mm. Find 1)the diameters of the Pulleys 2) the length and width of belt and 3) the belttension. (15)
4. a) A full journal bearing 100 mm diameter takes a radial load of 5000 N. Thebearing is 100 mm long and the speed of the shaft is 400 rpm. Thepermissible minimum film thickness is 0.025mm and diametral clearance is0.152 mm. find viscosity of a suitable oil b) co-efficient of friction c) heatgenerated d) amount of oil pumped through bearing e) amount of endleakage and f) temperature rise of the oil flow through the bearing.
(15)
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ORa) List out the properties of lubricants and the purpose of lubricatio (5)b) A journal bearing 300mm long 150mm diameter carries a radial load of 9KN
at 1200 r.p.m.. The power lost in friction is 6KW. Viscosity of oil at roomtemperature is 0.018Pa-s. Find the diametral clearance. (10)
5. a) A reciprocating compressor is to be connected to an electric motor with thehelp of spur gears. The distance between the shafts is to be 500mm. Thespeed of the electric motor is 900r.p.m. and speed of the compressor shaftis desired to be 200r.p.m. The torque to be transmitted is 500N-m. Takingstarting torque as 25% more than the normal torque. Determine 1) Moduleand face width of the gears Using 20 stub teeth. 2) Number of teeth andpitch circle diameter of each gear. Assume suitable values of velocity factorand lewis factor. (15)
ORa) A cranked lever has the following dimensions. Length if the handle is
300mm, length of the lever arm is 400mm, overhang of the journal is100mm. The lever is operated by a single person exerting a Maximum forceof 400N at a distance 1/3rd the length of the handle from its free Hand. Thepermissible bending stress for the lever is 50 N/mm2 and shear stress Forthe shaft material is 40 N/mm2 . Find 1) Diameter of the handle 2) Cross-Section of the lever arm. 3) Diameter of the journal.
(15)
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12052 THERMAL ENGINEERING
6 Hrs/Week 16 Weeks /Sem.Total Hrs : 96
OBJECTIVES: Define various types of steam. Explain the of boiler Compare various types of boilers. Familiarize boiler mountings and accessories. Describe various circuits used in the steam power plant. Explain working of a nuclear power plant. Compare conventional energy sources with non conventional sources of
energy Appreciate the application of refrigeration and air- conditioning Define the various parameters used in psychometry Compare the different types of refrigeration & air- conditioning system.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12052-
ThermalEngineering
Hours/Week Hours/Semester Assessment Marks
6 96Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
Unit Topic TIME (Hrs)I. Steam and Expansions of Steam 18II. Steam Boilers and performance of boilers 18
III. Thermal power plant 18IV. Energy Engineering and management 18V. Refrigeration and Air Conditioning 18
Revision and test 6TOTAL 96
UNIT - I: STEAM AND EXPANSIONS OF STEAM: 18hrs
Introduction-formation of steam-t-h diagram-t-v-diagram-t-s-diagram-phase diagram-critical conditions-enthalpy of water-enthalpy of evaporation-conditions of steam-wet,dry and superheated steam-advantages of superheated steam-dryness fraction-enthalpy of wet, dry and superheated steam-specific volume of water and steam-density of steam-external work of evaporation-internal latent heat-internal energy ofsteam-entrophy of water and steam-steam tables-Mollier chart-problems.Expansion processes of steam-constant volume, constant pressure, constanttemperature, hyperbolic, isentropic, polytropic and throttling processes-problems.Steam calorimeters-bucket, combined separating and throttling calorimeters-problems.
85
UNIT - II: STEAM BOILERS AND PERFORMANCE OF BOILERS: 18hrs
Classification of boilers-high pressure boilers-Lamount and BHEL high pressureboilers-advantages of high pressure boilers, boiler mountings-function, constructionand working-boiler accessories-function, construction and working-comparison ofmountings and accessories-feed water treatment-methods-starting boiler from coldcondition- safety precautions in boiler operation-Indian boiler act.Performance of boilers-actual, equivalent and factor of evaporation-boiler efficiency-Factors influencing boiler efficiency-boiler power-problems-efficiency of economiserand super heater-problems-boiler trail-heat losses in a boiler-heat balance sheet-problems.UNIT - III: THERMAL POWER PLANT: 18hrs
Layout of thermal power plant -fuel and ash circuit -water and steam circuit - air andflue gas circuit - cooling water circuit -merits and demerits of thermal power plant -air pollution by thermal power plants -pollutant and effects of pollution-pollutioncontrol-cyclone separator-wet scrubber-electrostatic precipitator-control of No2 andSO2.Steam turbine-steam power cycle-Carnot, Rankine and modified Rankine cycles-classification of steam turbine-necessity of compounding-Industrial turbines.Steam condenses - elements of condensing plant-classification of condensers-jetcondenser types-surface condensers-types-merits and demerits of surfacecondensers-sources of air in condenser vacuum-vacuum efficiency-condenserefficiency-mass of cooling water required-mass of air presen-number of tubes-problems.
UNIT - IV: ENERGY ENGINEERING AND MANAGEMENT: 18hrs
Nuclear fuels-requirements-fissile and fertile fuels-Nuclear fission and fusion-chainreaction-radio activity-layout of nuclear power plant-merits and demerits-Nuclearreactors-classification-components of nuclear reactor-reactor core-moderators-control rods-coolant-reflectors-biological shield-pressurised water reactor-boilingwater reactor-Candu type reactor-fast breeder reactor-effect of nuclear radiation-disposal of nuclear wastes-comparison of nuclear power plants with thermal powerplants.Conventional sources of energy-layout of hydel and diesel power plants-merits anddemerits.Non-conventional sources of energy- solar-wind-tidal-geothermal and gobar gasplant
UNIT - V: REFRIGERATION AND AIR CONDITIONING: 18hrs
Refrigeration-refrigerators and heat pumps-types and applications of refrigeration-vapour compression refrigeration system-vapour absorption system-comparison-refrigerating effect-capacity of refrigerating unit-C.O.P-actual C.O.P-power required-mass of ice produced-problems-C.O.P of reversed Carnot cycle-Bell-Coleman cycle-problems-refrigerants-desirable properties-classification of refrigerants.Air conditioning-psychometric properties-dry air-moist air-water vapour-saturated air-dry bulb temperature-wet bulb depression-dew point depression-dew pointtemperature-humidity-spcific and relative humidity-psychometric chart-psychometricprocesses-sensible heating and cooling-humidification-dehumidification-simpleproblems using psychometric chart-air conditioning-classification and applications ofair conditioning system-room air conditioning -central air conditioning-comparison-differences between comfort and industrial air conditioning-factors to be consideredin air conditioning-loads encountered in air conditioning systems.
2. R.S.Khurmi and J.K.Gupta, Thermal Engineering, Edn. 18, published by S.Chand & Co., Ram Nagar, New Delhi 110 055.
Reference Books:
1. R.K.Rajput, Thermal Engineering2. B.K.Sarkar, Thermal Engineering, Edn. 3, 1998, published by Dhanpat Rai &
Sons, 1982, Naisarak, New Delhi 110 006.3. S.Domkundwar, A.V.Domkundwar S.C.Arora, Power plant Engineering
4. Nagpal, Power plant Engineering, Edn. 8, published by by 24, KhannaPublishers, 2B, North Market, Naisarak, New Delhi 110 006.
5. P.C.Sharma, Power plant Engineering6. G.D.Rai, Non Conventional Energy sources, Edn.4, Published by 24, Khanna
Publishers, 2B, North Market, Naisarak, New Delhi 110 006.7. P.L.Ballaney, Refrigeration and Air condition, Edn. 4, published by by 24, Khanna
Publishers, 2B, North Market, Naisarak, New Delhi 110 006.8. Manohar Prasad, Refrigeration and Air-condition, 1993, Edn. Published by
H.S.Popali for Wiley Eastern Ltd., 4835/24 Ansari Road, Daryaganj, New Delhi110 053.
87
12052 THERMAL ENGINEERINGMODEL QUESTION PAPER – I
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. What is wet steam?2. Write expression for enthalpy of super heated steam.3. State the function of fusible plug in a boiler.4. Define Boiler efficiency.5. State the major pollutants from power plants.6. What is a steam condenser?7. Give examples of fissile fuels.8. What is Radioactivity?9. Define C.O.P of Refrigeration unit.10. What is Humidity?
PART –B Answer all the questions 3x5=15
11. State the advantages of super heated steam.12. State the main clauses of Indian Boiler Act.13. List out factors to be considered while selecting a site for Thermal power
plant.14. Explain chain reaction with a sketch.15. Explain any one of the Psychometric processes
PART –C Answer any one question from each unit10x5=50
16. 1. Determine the enthalpy, external work of evaporation and entropy of 2kg ofwet steam having dryness fraction 0.9 at a pressure of 10bar. (10)
OR2. Describe the working of separating and throttling calorimeter with a sketch.
(10)
17. 1. A Boiler generates 750 kg of steam per hour at 11 bar absolute and 40º csuper heat and turns 100kg cal per hour. If the calorific value of coal is 29,300kj/kg feed water temperature 45ºC. Cps=2.09kj/kg.k. Calculate a) factor ofevaporation. B) equivalent evaporation C) Boiler Efficiency. (10)
OR2. Explain with sketches the working of the following mountings in a boiler.
a) Lever Safety valve.b) Pressure gauge. (10)
18. 1. Explain the following with sketches in a Thermal power plant.a) Fuel and Ash circuitb) Water and steam circuit. (10)
OR2. Explain with sketches the construction and working of
a) Any one Jet condenserb) Any one Surface Condenser (10)
88
19. 1. Describe the working of candu type reactor with a sketch. (10)OR
2. Explain the working of a Bio-gas plant with a sketch. (10)
20. 1. Explain with a line diagram the vapour compression method of refrigeration.(10)
OR2. Describe the working of window type air-conditioning system with a sketch.
(10)
89
12052 THERMAL ENGINEERINGMODEL QUESTION PAPER – II
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Define dryness fraction of steam.2. What do you understand by internal energy of steam3. What is a Fire Tube Boiler?4. Name any four Boiler Mountings.5. Name the Four important circuits of a steam power plant.6. State the principle of working of an impulse turbine.7. State the main elements of a nuclear power plant8. Name any two reactors currently used in our country.9. Define the term ‘Refrigerationr’.10. What is meant by air-conditioning?
PART –B Answer all the questions 3x5=15
11. Determine the condition of steam at a pressure of 20 bar and 2520 kJ/kg heat isrequired to generate this steam from water at 0ºc.
12.Define the following terms a) Actual evaporation b) Equivalent Evaporationc) factor of Evaporation.
13. Explain with a sketch the principle of working of a reaction turbine.14. Draw a neat sketch of a nuclear reactor. Name the various components.15. Mention any five applications of refrigeration.
PART –C Answer any one question from each unit10x5=50
16. 1. Steam at a pressure of 4 bar absolute and 0.75 dry is heated at constantvolume to a pressure of 5 bar (abs). Find the final condition of steam and heatabsorbed by one kg of steam. (10)
OR2. a) Explain the various stages in the formation of steam. (4)
b) Find the specific volume of the steam when its pressure is 7 bar and thecondition of steam is(i) wet having dryness fraction of 0.9 and (ii) Superheated to atemperature of 250°c. (6)
17. 1. Describe with a neat sketch the working of Lamont boiler(10)
OR2. The following results were obtained in a boiler trial feed water per hour=750kg
at 25ºc. Steam produced – 0.95 dry at 8 bar, coal used per hour – 100kg.Calorific value of coal is 27300 kJ/kg. Ash and unburnt coal collected frombeneath fire bars – 8kg/hour of calorific value 2800 Kj/Kg. Mass of flue gasper kg of coal burnt – 17kg. Flue gas temperature-325ºc, air temperature –15ºc. Specific heat of the flue gases-1.03kJ/kg.k. Calculate (i) BoilerEfficiency (ii) Prepare a heat balance sheet.
(10)
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18. 1. Explain the working of following with suitable sketchesa. Back Pressure turbineb. Exhaust Turbinec. Bleeder Turbine (10)
OR2. During a trial on a condenser the following readings were taken. Barometer
reading – 766mm of mercury. Actual vaccum recorded by gauge – 716mm ofmercury. Mean temperature of condenser – 34ºc temperature of hot well –29ºc. Inlet temperature of cooling water-15ºc. outlet temperature of coolingwater-24ºc. Determine (i) corrected vaccum (ii) vacuum Efficiency (iii)Condenser Efficiency. (10)
19. 1. Describe with a neat sketch the construction and operation of Fast breederreactor.
OR2. a) Discuss the merits and demerits of a nuclear power plant. (5)
b) Explain any one method of using solar energy for power generation.(5)
20. 1. Find the least KW required by a perfect reversed heat engine that will make450kg of ice per hour at-3ºc from water at 20.5ºc. Take latent heat of ice as340 kJ/kg and specific heat as 2 kJ/kg. (10)
OR2. a) Explain the following terms (i) humidity (ii) Specific humidity and
(iii) Relative Humidityb) Explain the various loads encountered in an air conditioning system.
(10)
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12071 REFRIGERATION AND AIR CONDITIONING
6 Hrs/Week 16 Weeks /Sem.Total Hrs : 96
OBJECTIVES: Explain the working of open and closed air system of refrigeration. Describe the working and construction of compressors used for air
conditioning. Explain vapour compression refrigeration system. Explain vapour absorption refrigeration system. Compare the properties and applications of various refrigerants. Define the parameters used in psychrometry. Use Psychrometry chart Describe the equipment used for air conditioning. Estimate the cooling load for the given requirement. Explain the industrial application of refrigeration.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12071-
Refrigeration andAir conditioning
Hours/Week
Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
UNIT TOPIC TIME ( Hrs )I. Refrigeration system and Refrigeration equipments 18II. Vapour compression refrigeration system and Vapour
absorption refrigeration system18
III. Refrigeration flow controls, refrigerants and lubricants andApplications of refrigeration
18
IV. Psychrometry and comfort air conditioning 18V. Air conditioning systems and Cooling load calculations 18VI. Revision Test 6
TOTAL 96
UNIT I REFRIGERATION SYSTEM AND REFRIGERATION EQUIPMENTS18 Hrs
Refrigeration system: Thermodynamic state of a pure substance, modes of heattransfer –laws of heat transfer - mechanisms of production of cold - unit ofrefrigeration –types of refrigeration –reversed Carnot cycle - C.O.P of heat engine-heat pump- refrigerating machine – principle of working of open and closed airsystem of refrigeration – advantages and disadvantages – and its application of aircycle-problemsRefrigeration Equipments: Compressor – principle of working and constructionaldetails of reciprocating and rotary compressors, hermetically and semi hermeticallysealed compressors- condensers-principle of working and constructional details of aircooled and water cooled condensers, evaporative condensers- advantages anddisadvantages - natural and forced draught cooling towers.Evaporators- natural circulation and forced circulation type – principle of workingconstructional details.
92
UNIT II VAPOUR COMPRESSION REFRIGERATION SYSTEM AND VAPOURABSORPTION REFRIGERATION SYSTEM 18 Hrs.
Vapour Compression Refrigeration System: Principle of working of vapourcompression system – analysis of vapour compression cycle using T-s diagram andp-H diagram- refrigerating effect- compression work - C.O.P - effect of superheatingand under cooling - problems – effect of - evaporative pressure - condenser pressure- liquid –vapour refrigeration heat exchangers - advantages and disadvantages ofsuperheating and under cooling –use of flash chamber and accumulator.
Vapour Absorption Refrigeration System: Simple absorption system – Electroluxsystem -NH3 and lithium Bromide system – solar absorption refrigeration system-absorption system comparison with mechanical refrigeration system.
UNIT III REFRIGERATION FLOW CONTROLS, REFRIGERANTS ANDLUBRICANTS AND APPLICATIONS OF REFRIGERATION 18 Hrs.
Refrigerant flow controls, refrigerants and lubricants: Capillary tube-automaticexpansion valve-thermostatic expansion valve-solenoid valve-evaporator pressureregulator –suction pressure regulator-selection of a refrigerant-properties andapplications of following refrigerants SO2 , CH4 , F11, F12 ,F22, and NH3 –CFCsrefrigerants- equivalent of CFCs refrigerants (R-123a,R-143a,R-69S)- lubricants usedin refrigeration and their applications.Applications of refrigeration: Slow freezing –quick freezing- cold storage-frozenstorage-freeze drying –dairy refrigeration –ice cream cabinets-ice making – watercooler, milk cooler, bottle cooler-frost free refrigeration.
UNIT IV PSYCHROMETRY AND COMFORT AIR CONDITIONING 18 Hrs.
Definitions of dry air, moist air, water vapour, Avagadro’s law, Dalton’s law of partialpressure - dry and wet bulb temperature - dew point - humidity - specific andabsolute - relative humidity - degree of saturation - enthalpy of moist air- adiabaticsaturation of air by evaporation of water- psychometric chart and its uses –psychometric processes – sensible heating and cooling - humidifying and heating -dehumidifying and cooling - adiabatic cooling with humidification - total heating orcooling processes -sensible heat factor - by pass factor with simple problems –governing optimum effective temperature – comfort chart-design consideration.
UNIT V AIR CONDITIONING SYSTEMS AND COOLING LOAD CALCULATIONS18 Hrs.
Air Conditioning Systems: Equipment for air conditioning and insulation factors –air purification – temperature control – humidity control – dry and wet filters-centrifugal dust collector – air washer humidifier – dehumidifier - fans and blowers –grills and registers – summer and winter air conditioning, window type air conditioner– central plant system – properties of ideal insulator, types of insulating materials –airdistribution and duct systems – tools and installation, servicing and maintenance of R& AC systems.Cooling load calculations: Different heat sources – conduction heat load –radiation load of sun – occupants load – equipment load - infiltration air load –miscellaneous heat sources –fresh air load - simple problems.
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Revision and Test 6 Hrs
Text books :
1. P.L . Ballaney, Refrigeration and air conditioning, Khanna Publishers, 2B,North Market, Naisarak, New Delhi 110 006.
2. V.K. Jain, Refrigeration and air conditioning
Reference Books:
1. Domkundwar, A course in refrigeration and air conditioning2. Dossat , Principles of refrigeration3. Audels, Home refrigeration and air conditioning, 1996 Edn., published by
Theo. Audel & Co. publisher, 49, West 23rd Street, New York. - 19984. C.P Arora, Refrigeration and air conditioning
94
12071 REFRIGERATION AND AIRCONDITIONINGMODEL QUESTION PAPER – I
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Define COP of a refrigeration system.2. State Carnot theorem.3. The gauge reading of a refrigerant cylinder is 150 PSIG. What is the absolutepressure.3. State any two disadvantages of superheating.4. What is the function of accumulator in a VCR system.5. Give some two desirable properties of refrigerant.6. State any two application of refrigeration system.7. State the Daltons law of partial pressure.8. Define the term dew point temperature.9. What is meant by air washer.10.What are the various heat loads in an air conditioning system.
PART –B Answer all the questions 3x5=1511. Explain in short the operation of a reciprocating compressor.12. With the neat sketch explain the working of solar absorption refrigertionsystem.13. What are the factors to be considered for the selection of a refrigerant.14. Define the terms dry bulb temp., wet bulb temp., dew point temp., specifichumidity and
absolute humidity.15. With the neat sketch explain the working of centrifugal dust collector.
PART –C Answer any one question from each unit10x5=5016. 1. (a) Define conduction convection and radition modes of heat Transfer.
(3)(b) A refrigeration system works between the temp limits of 37 degree
celsius and -13 degree celsius. Find the amount of ice that will beproduced per Kwh at 260k from water available at 27 degree celsius.Take cp of ice and water as cpi=2.09kj/kg-k and cpw=4.197kj/kg-k andhs=335kj/kg. (7)
(OR)2. (a) With the neat sketch explain the working of different types of
condensers. (5)(b) Explain the working of any one type of cooling towers. (5)
17. 1. Explain with the neat sketch the working of vapour compression refrigertionsystem. (10)
(OR)2. With the neat sketch explain the working of vapour absorption
refrigeration system (10)
18. 1. (a) Give the various application of refrigeration system. (5)(b) List out the affects caused by using various refrigerants to the
environment. (5)
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(OR)2. (a) Explain the working of slow freezing and quick freezing refrigeration
system. (5)(b) List out some of the absoluble properties of refrigerants. (5)
19. 1. The values obtained from a sling psychrometer are tlb=30 degree celsiusand twb=20 degree celsius. The barometric reading is 740mm of Hg.Calculate (i) dew point temp and relative humidity. (ii) degree ofsaturation (iii) specific humidity (iv)specific volume (v) specific enthalpy.
(OR)(10)
2. (a) Define the term psychrometer an psychrometry (4)(b) Draw the neat layout of the psychrometric chart and indicate thevarious processers available on it. (6)
20. 1. Explain the working of window type air conditioning with the sketch. (10)(OR)
2. With the neat sketch explain the working of a centralized air conditioningsystem. (10)
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12071 REFRIGERATION AND AIRCONDITIONINGMODEL QUESTION PAPER – II
DURATION : 3 HRS. MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Define a ton of refrigeration.2. Define COP of a refrigeration system.3. Draw the T-s and P-h diagram of a vapour compression refrigeration system.4. Give two advantages of VCR system over VAR system.5. What are the lubricants used in the refrigeration system.6. What is the use of capillary tube in a refrigeration system?7. State the Daltons law of partial pressure.8. Define sensible heat and latent heat.9. What are the materials used as insulators in air conditioning system.10. What are the various heat loads in an air conditioning system.
PART –B Answer all the questions 3x5=15
11. Explain the working of evaporative condensers with neat sketch.12. Give some five differences between the VCR system and VAR system.13. What are the factors to be considered for the selection of refrigerant?14. What is meant by psling psychrometer. Explain the process of cooling and
dehumidification and heating and humidification with the use of psychometricchart.
15. Explain the material used and working of dry and wet filters.
PART –C Answer any one question from each unit10x5=50
16. 1. (a) Define conduction, convection and radiation modes of heat transfer.(4)(b) A 15 ton refrigeration system working on the simple air refrigerationcycle takes 0.6kg/sec of air from the main compressor. From the givenvalues obtained the cop and the power needed and the amount of flud tobe evaporated per hour if the enthalpy charge is 260kJ/kg. PI=1.05 barP2=5.25 bar P cabin=1.02bar T1=288k 10mp=0.8, cooling turbineefficiency=o.76. air 1cares the cabin at 30 degree celsius, heat exchangereffectiveness=0.75. (6)
(OR)2. (a) Explain the working of any one type of cooling tower. (5)
(b) With the neat sketch explain the working of different types ofcondensors. (5)
17. 1. Explain the working of vapour compression refrigeration system with theneat sketch. (10)
(OR)2. Explain with sketch the working of Electrolux refrigeration system. (10)
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18. 1. (a) Give the various application of refrigeration system. (5)(b) List out the effects caused by the using various refrigerants to the
environment (5)(OR)
2. (a) List out some of the desirable properties of refrigerants. (5)(b) Explain the working of slow freezing and quick freezing refrigeration
system. (5)
19. 1. The values obtained from a sling psychrometer are tdb=30 degree celsiusand tub=20 degree celsius. The barometric readings is 740 mm of Hg.Calculate (i) dew point temp and relative humidity (ii)degree of saturation(iii) specific humidity (iv) specific volume (v)specific enthalpy. (10)
(OR)2. Explain the various psychrometric process in detail with the
psychrometric chart. (10)
20. 1. (a) State the working of air blowers with the neat sketch. (5)(b) Explain the working of centrifugal dust collector with the sketch. (5)
(OR)2. Explain the working of centralised air conditioning system with the neat
sketch. (10)
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12072 : METROLOGY, MACHINE TOOL MAINTENANCE AND TESTING
6 Hrs/Week 16 Weeks/SemTotal Hrs : 96
OBJECTIVES:
State the objectives of metrology and define various terms Explain the working principles of mechanical, electrical and optical measuring
instruments. Describe the construction and operating procedures and applications of
linear, angular and taper measuring instruments. Compare various methods of measuring external thread Explain the different methods of measuring internal thread nomenclature. Explain the various methods of measuring gear tooth thickness and tooth
profile. Represent the surface finish as per BIS code. Compare the various methods of measuring surface inspection. State the importance, types and uses of comparators. Describe the construction, procedure of usage of major mechanical
comparators. Describe the construction procedure of usage of major electrical/electronic
comparators. Describe the construction procedure of usage of major pneumatic and optical
comparators Explain the working and applications of CMM Explain the various machine tool tests generally carried out. Explain the maintenance procedure of standard machine elements.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12072- Metrology,
Machine ToolMaintenance and
testing
Hours/Week
Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
UNIT TOPIC TIME (Hrs)
I Standards of Measurements & Principles of MeasuringInstruments
18
II Linear, Angular & Taper Measurements 18
III Measurement of Threads and Gears 18
IV Measurement of Surface Finish & Comparators 18
V Machine tool testing and maintenance 18
Revision, Test 6
Total 96
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UNIT-I STANDARDS OF MEASUREMENTS & PRINCIPLES OF MEASURINGINSTRUMENTS 18 hrs
Introduction to metrology – Objectives of Metrology – Precision and Accuracy –Standards of Measurements: Line standard, End Standard, Wavelength Standard –Classification of Standards – Characteristics of line and end standards.Sources of errors – Classification of measuring instruments – Selection ofinstruments – Principles of measuring instruments: Mechanical, Optical, Electricaland Pneumatic measuring principles.
UNIT-II LINEAR, ANGULAR AND TAPER MEASUREMENTS 18 hrs
Angular Measurements: Bevel Protractors and its types – Sine bar, Sine table andSine centre – Angle gauges – Microptic Autocollimator and Angle Dekkor -Clinometer.Taper Measurements: Gauges for tapers – Measurement of taper shafts –measurement of taper holes.
UNIT-III MEASUREMENT OF THREADS AND GEARS 18 hrs
Threads: External screw thread measurements: Measurement of Major dia, Minordia, Effective dia and Pitch – Internal screw thread measurements: Measurement ofMajor dia, Minor dia, Effective dia and Pitch – Screw thread gauges.Gears: Gear tooth terminology – Sources of errors in manufacturing of gears –Measurement of tooth thickness: Gear tooth vernier, Constant chord method,Addendum comparator method and Base tangent method – Measurement of toothprofile: Tool maker’s microscope or projector, Involute tester – Measurement of pitch– Measurement of run out – Lead and Backlash checking .- Measurement ofconcentricity – Alignment of gears – Composite errors: Master gear, Parkinson’s geartester.
UNIT-IV MEASUREMENT OF SURFACE FINISH & COMPARATORS 18 hrs
Measurement of Surface Finish : Representation of surface finish as per BIS –Methods of measuring surface finish: Comparison method and Direct instrumentmeasurements – Surface inspection by comparison methods: Touch inspection,Visual inspection, Scratch inspection, Microscopic inspection, Comparison withstandard specimen, Surface photographs – Direct instrument measurement:Intersectional method, Interference method and Stylus method .Features of comparators – Uses of comparators – Types of comparators –Mechanical comparators: Dial indicator, Reed type and Sigma comparators – Opticalcomparators: Optical lever, Simple optical comparator, Cooke and Zeiss optimeter –Electrical/Electronic comparators: Electrical comparator, Electro-mechanicalcomparator, Electro-limit gauges, Electronic comparator and Electronic measuringequipment – Pneumatic comparators: Solex pneumatic comparator, Air gaugingimportant characteristics.
100
UNIT-V MACHINE TOOL TESTING AND MAINTENANCE 18 hrs
Machine Tool Testing: Introduction – Machine Tool tests – Instruments required foralignment tests – Alignment test on lathe – Alignment tests on drilling machine –Alignment tests on milling machine – Acceptance test for surface grinders.Bearing inner race loose on shaft – Housing bore loose on shaft – Bearing runningdry – Mis-alignment – Damaged one or more balls/rollers – Radial play – Assemblyof bearing unit.Key – Shaft/housing key-way – Disassembly of keyed joints – Assembly of keyedjoints.Lead Screw Repair: Thread wears up to 0.3 mm – Thread wear exceeding 0.3mm –Repairs of lead nut – Elimination of play.Spindle Shank & Journal Seats: Repair standards, Repair methods for bush bearingseats, Repair methods for ball/roller bearing seats.Taper Bore: Repair standard, Repair methods – Threads: Repair standards, Repairmethods – Keyways: Repair methods.
12072 METROLOGY, MACHINE TOOL MAINTENANCE AND TESTINGMODEL QUESTION PAPER – I
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.
Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Explain the term ‘Accuracy’2. What are the objectives of engineering metrology?3. Define Least Count of vernier Caliper4. What precautions should be taken while using slip gauges?5. Define Pitch6. Define Backlash7. What is a Comparator?8. What is microscopic inspection?9. What is meant by alignment tests on m/c tools10. What is meant by radial play?
PART –B Answer all the questions 3x5=15
11. Distinguish between Line standard & End standard.12. State the principles of optical measuring instruments.13. What is sine bar? Give its uses14. Write short note on Angle dekkor.15. Describe any one method of measuring effective diameter of internal threads.
PART –C Answer any one question from each unit10x5=50
16. 1. a) Describe the following types of errors and state how they can be takencare of. (i)Environmental error (ii) Parallax error (6)b)Define Precision and Accuracy (4)
OR2. Name the various methods of measurements and explain any three of
them with suitable examples. (10)17. 1. State the principle of Vernier instrument explain briefly the construction
and use of vernier caliper with a neat sketch. (10)OR
2. a) Explain a sine bar used for angular measurements. (5)b) Explain measurement of Tapper Shaft. (5)
18. 1. Describe the following methods of measuring the effective diameter of thescrew threads: (i) Thread micrometer method ii) Onewire method (10)
OR2. Describe the Parkinson’s gear tester and state its limitations. (10)
19. 1. a) With the help of a neat sketch describe the principle of working of amechanical Comparators. (6)b) Explain simple optical comparator. (4)
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OR2. What are roughness comparison specimens? How they assess surface
specimen? What are their limitations? (10)
20. 1. Explain the procedure of ‘alignment tests’ to be done on a milling machine.(10)
OR2. Explain the procedure of ‘alignment tests’ to be done on a lathe. (10)
103
12072 METROLOGY, MACHINE TOOL MAINTENANCE AND TESTINGMODEL QUESTION PAPER – II
DURATION : 3 HRS.
MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. Explain the term ‘Precision’2. What are precision linear measuring instruments?3. What is the Least Count of Vernier Caliper and Micrometer?4. Define linear measurement5. Give formula for (i) Base pitch (ii) Dimetral pitch6. Define Run out.7. Give reasons Mechanical comparators are less accurate as compared tooptical comparators.8. Which instrument is used for measuring surface finish deep bores?9. What are the applications of autocollimeter?10.What is the effect of keyway cut on a shaft?
PART –B Answer all the questions 3x5=15
11. Name the various types of errors in gears.12. What are the advantages & disadvantages of electrical comparator.13. Explain the term
(i) Ra value(ii) Rz value
14. What are the geometrical checks to be done on a m/c tool?15. What is meant by alignment tests on m/c tools? Why they are necessary?Explain.
PART –C Answer any one question from each unit10x5=50
16. 1. a) What are the objectives of metrology. (4)b) Explain principles of mechanical measuring instruments. (6)
OR2. Explain the measuring of external angle of a component using any one
type of precision measuring device with suitable sketch. (10)
17. 1. State the principle of a micrometer. Sketch a outside micrometer andname its various parts.
OR2. Explain construction and user Vernier bevel protractor and optical bevel
protractor. (10)
18. 1. With the help of a neat sketch explain the construction, working andapplications of toolmakers microscope. (10)
OR2. a) What are the sources of errors in manufacturing of gears? (5)
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b) Explain measurement of concentricity. (5)
19. 1. Name the various methods of inspecting the surface finish by comparison.State their advantages and limitations. (10)
OR2. Describe the construction and working of a optical projector. (10)
20. 1. Explain the procedure of ‘alignment tests’ to be done on a drilling machine.(10)
OR2. Distinguish between alignment test and performance test of a machine
tool.Discuss with neat sketches, how you would test any three of the following
for a lathe.(i) Spindle centre run-out (ii) Spindle taper bore run out
(iii) chunk run out (iv) Cross slide alignment(10)
105
11011 ENGLISH COMMUNICATION PRACTICAL
(Common to all Branches)
Curriculum Outline
The course on English Communication Practical will enable the learners developtheir Communication skills in English, especially at a time when the Info-TechExplosion on one side and the search for Communicational Exploration on the otherhave been taking the contemporary world by leaps and bounds. Keeping in view thecareer requirements of the students at Diploma level, the course on EnglishCommunication Practical has been designed in such a way that it will enable thelearners acquire the much needed proficiency in the art of Communication and thiswill go a long way in shaping and fine tuning the future career of the students.
OBJECTIVES:
To equip the learners with effective speaking and listening skills in English To make them realize the communication potential of English language To infuse in their minds the much-needed and all the more important
‘CONFIDENCE’ To facilitate them to acquire a fairly acceptable skill in pronunciation To train them to use language effectively to face interviews, group
discussions and public speaking To enable them to prepare their resume, curriculum vitae etc., To promote ethical values and inculcate organizational behaviour…
For achieving the objectives identified above, the following skills are to be developedto enhance the communicative potential of the students.
The Skills are:1. Listening2. Reading and Pronunciation3. Speaking and Presentation4. Writing
SCHEME OF INSTRUCTION AND EXAMINATION
SUBJECT INSTRUCTION EXAMINATION
Hours/WeekHours/
Semester
Assessment MarksDuratio
nInternalBoard
Examination
Total
11011 EnglishCommunication
Practical4 64 25 75 100 3 Hrs.
106
TOPICS AND ALLOCATION
UNIT INSTRUCTION TIME (Hrs)
I Listening 12II Reading 12III Speaking 14IV Writing 8V Professional Ethics & Organizational Behaviour 8VI Project Report Writing (Outline) 2
Revision and Tests 8TOTAL 64
DETAILED SYLLABUS
UNIT I LISTENING
Listening to pre-recorded short episodes, conversations, passages, stories, (hardcopy of the material and cassettes) news bulletin, speeches by famous personalities– Listening for general and specific information etc.,
NOTE: The exercises given to the students must be recorded in the RecordNotebook.
UNIT II READING
Reading aloud – by students individually - reading rhymes – proverbs – passages onvarious topics of interest – Newspaper reading – Reading humorous passages –Anecdotes – Stories – tricky sounds (conditioners) – Reading manuals – Readingindividual sentences with articulation, pronunciation, Tones, Punctuation, pausesetc…- Reading the titles of popular books, movies and poems.
NOTE: All the exercises given in Reading skills should be written in the RecordNotebook.
UNIT III SPEAKING
i. Self-introduction – introducing one self, one’s family – one’s friends andrelatives, one’s language – one’s country etc…
ii. Welcome Address, Vote of thanksiii. Extempore speeches.iv. Short speech on simple topics on simpler themes for about one minute.v. Role play – Group Discussion – Debate – Seminars – Machine Descriptions
(depending upon branches) – Compering – Interviewing others by AskingQuestions – Interview Techniques – Conversational Practice – TelephonicConversation – Telephonic Interviews – How to establish conversation /dialogues – Entry Attempts/Admissions.
NOTE: Items taught in the Speaking skill should be written in the RecordNotebook.
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UNIT IV WRITING
i. Writing Resume, preparing Curriculum Vitae.ii. Converting newspaper headlines into sentences.iii. Formation of Sentences – Using the table of Sentence-making and producing
multiple sentences.iv. Framing Questions for the responses givenv. Tips for better performance in interviews.vi. Describing Objectsvii. Describing Situations.
NOTE: All the above topics must be taught to the students providing sufficientmodels and
exercises and everything must be recorded in the Record Notebook.
UNIT V PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR:
Different kinds of Ethics – Ethics in different fields – Engineering Ethics – Senses ofEngineering Ethics – Moral Values – Integrity & Loyalty – Work Ethics – Respect forothers and authority – Empathy – Caring and Sharing – Honesty – Courage andCommitment – Valuing Time – Co-operation & Teamwork – Safety and Risk – RightAction – Professional ideals and virtues – Individual’s Ambition – Conflict Resolution– Self-Confidence – Customs and Manners – General Behaviour – Etiquettes to befollowed – Professional Responsibility – Accountability – Leadership Qualities –Effective Communication skills.
UNIT VI PROJECT REPORT WRITING (Outline):
Significant features of Project Report Writing – Organization – Presentation – Use ofImpersonal Passives – Acknowledgements.
REFERENCES
UNIT I LISTENING:
Cassette with books:
1) Spoken English for you – Level I & Level II by Radha Krishna Pillai –Emerald Publishers.
2) Activity Sheets to be prepared.3) BBC – Lingophone with Hard copy.4) World Great Speeches – Book – Balaji’s – Famous Speeches.
UNIT II READING:
1) Short story Books (Indian Writing – Panchathanthra)2) Reading Illustrated Books (Gokulam – Wisdom – Chandamama –
Amarchitrakatha) must be subscribed.
UNIT III SPEAKING:
Books / materials related to speaking skill.
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UNIT IV WRITING:
1) Internet Browsing and collecting information for C.V.2) Book materials / Cassettes for writing skill.3) Guided composition in English Language Teaching – Alexander L.G.
Longman, 1971.4) The Language Laboratory and Language Learning – Dahim Longman,
London, 1967.
PROFESSIONAL ETHICSREFERENCE BOOKS
1. Mike Martin and Roland Schinzinger, “Ethics in Engineering”, McGraw Hill,New York 1996.
2. Charles D. Fleddermann, “Engineering Ethics”, Pearson Education / PrenticeHall, New Jersey, 2004.
3. Charles E. Harris, Michael S. Protchard and Michael J Rabins, “EngineeringEthics” – Concepts and Cases”, Wordsworth Thompson Learning, UnitedStates, 2000.
4. Edmund G Seebauer and Robert L Barry, “Fundamentals of Ethics forscientists and Engineers”, Oxford University Press, Oxford, 2001.
5. G.E. Moore, “Elements of Ethics”, Temple University Press, Philadelphia,1991.
7. May Mothersill, “Ethics”, The MacMillan, New York, 1965.8. Raymond Bradley and Stephen Duguid, “Environmental Ethics”, Vol I & II,
Simon Fraser University, Canada 1989.9. Kevin W. Bowyer, “Ethics and Computing – Living Responsibility in a
computerized World”, IEEE Computer Society Press, California, 1996.10. Jayashree Suresh and B.S. Raghavan, “Professional Ethics”, S.Chand &
Company Ltd., New Delhi, 200511. James V. McGlynn, Jules J. Toner, “Modern Ethical Theories”, The Bruce
Publishing Company, Milwaukee, 1962.
ENGLISH COMMUNICATION PRACTICAL(Common to all branches)
LABORATORY REQUIREMENT
1. An echo-free room.2. Public Address System3. A pair of collar microphones with amplifiers and speakers4. Headphone units – 30 Nos. with one control unit with a facility
to play and record in cassettes.5. Colour Television (minimum size – 61”)6. DVD/VCD Player with Home Theatre speakers7. Clip Chart, white board.8. Necessary furniture and comfortable chairs
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ENGLISH COMMUNICATION PRACTICAL(Common to all branches)
GUIDELINES
UNIT I LISTENING
a. The students must have been trained on a minimum of 10 Passages / stories/ speeches / episodes / news bulletin (about 200-250 words each) and allother topics given in the syllabus during their course of study.
In the examination a passage shall be played back for about 5 minutes from apre-recorded cassette followed by 5 questions. Students may be allowed totake notes while listening and they shall answer the questions in writing andassessment shall be made depending upon their performance.
b. The students must have been trained on a minimum of 10 dialogues duringtheir course of study.
In the examination a dialogue (face-to-face conversation) running for about5minutes shall be played back from a pre-recorded cassette (either Video orAudio) followed by 5 questions. The students may be allowed to take noteswhile listening and they shall answer the questions in writing. Assessmentshall be made depending upon the performance of the students.
UNIT II READING
The Students should have been trained to read out / articulate at least 200different types of sentences. They should also be trained to pronounce 200words (monosyllabic, by-syllabic, tri-syllabic and polysyllabic words) and allother topics given in the syllabus. The words and sentences are to be chosenin such a way that the tongue is articulating the sounds in the manner peculiarto the English Language. The students should also be trained to read aloudnewspaper headings, proverbs, rhymes, poems, (use of) minimal pairs andother items identified in the syllabus.
The students should also be exposed to 44 sounds in English language andtheir symbols with examples. However questions need not be asked in this inthe end examinations.
UNIT III SPEAKING
The students should have been trained on a minimum of 10 topics / role-play /group discussion / debate / seminar and other topics given in the syllabus.The students must also be trained to introduce themselves and others. Eachstudent must speak at least 10 sentences. The students must be givenguidelines for making their presentation / speech effective.
UNIT IV WRITING
The students should be thoroughly trained in all the items identified in thesyllabus under writing.
110
UNIT V PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR
Around 50 questions dealing with PROFESSIONAL ETHICS &ORGANIZATIONAL BEHAVIOUR are given in the syllabus. In theexamination the students will be given 15 questions (selected out of 50questions) and they have to write short answers to any 10 questions. Thiscarries 20 marks.
Teachers are requested to refer the reference books given in the syllabus andhelp the students to find out the answers for all the 50 questions.
UNIT VI PROJECT REPORT WRITING (Outline)
Elaborate guidelines must be given to the students as to how to write aProject Report. They must be exposed to the salient features in writing theProject Report. The students will be expected to submit outline of a ProjectReport relevant to their branches of study in a separate folder and this will beassessed at the time of End Examination and marks will be awardedaccordingly.
ENGLISH COMMUNICATION PRACTICAL(Common to all branches)
SCHEME OF EXAMINATION
END EXAMINATION (75 Marks)
1) End examination will be conducted for duration of 3 Hrs. covering all the sixunits identified in the syllabus.
2) The examination should be conducted in such a manner that there must beenough evidence regarding the performance of the students and thedistribution of marks for the academic audit.
INTERNAL ASSESSMENT (25 Marks)
1) Students will maintain a 150-page Record Notebook for all the activities donein the English Communication Lab., for which 20 marks will be allotted.
2) 5 marks will be awarded for attendance.
Annexure: A statement of allocation of marks.
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Time and Marks Allocation for each unit:
GROUP UNIT TIMEMARKS
ALLOTTED
GROUP A(Written Test)
PROFESSIONAL ETHICS &ORGANIZATIONAL BEHAVIOUR (UNIT V)
30Minutes
20
WRITING (UNIT IV )30
minutes10
LISTENING (UNIT I )30
minutes10
GROUP B(Oral Test)
READING (UNIT II)45
minutes10
SPEAKING (UNIT III)45
minutes15
GROUP C(Report
Submission)
PROJECT REPORT WRITING (UNIT VI) 10
GROUP A
1. PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR (20 Marks)
The students will be asked to write brief answers, for any 10 questions out of15 questions. The examiners will select the questions from the question bankgiven in the syllabus. Each question carries 2 marks. It will be a writtenpractical.Annexure: A question bank of 50 questions.
2. WRITING ( 5 + 5 = 10 Marks )
Out of 7 items identified in the syllabus under Writing skills, the students arerequired to answer for any two items out of four (i.e. 2 out of 4 questions).Each item carries 5 marks. There must be different questions for differentbatches.
3. LISTENING ( 5 + 5 = 10 Marks )
The students will be assessed on –a) Auditory Comprehension ( 5 marks )
A pre-recorded cassette on short episodes / passages / stories / news bulletin/ speeches by famous personalities (not exceeding 5 min.) will be played backonly once. The Students are required to listen to this play-back with utmostattention.
After that, a sheet of paper containing 5 questions on the topic (that wasplayed back to the students) with adequate space under each question (forthe students to write the answers) will be supplied. The students areexpected to write the answers in the space provided for each question.
112
Time for this exercise for the response of the students will be approximately10 minutes.
b) Audio Visual Comprehension ( 5 marks )
A face - to - face conversation (not exceeding 5 minutes) will be playedthrough a video or audio system (only once). The students are required tolisten to this conversation with full attention.
After that, a sheet of paper containing 5 questions on this exercise shall begiven with adequate space under each question for the students to write theanswer. Fill in the blanks type of questions may also be given to assess theListening skills of the students. Time to be taken by the students for thisexercise will be approximately 10 minutes.
The selection of topics such as short episodes/passages/stories/newsbulletins /speeches / dialogues etc… is left to the discretion of the internal andexternal examiners.
GROUP B
1. READING ( 5 + 5 = 10 Marks )
a) Each student will have to read aloud a passage of about 200 words. ( 5 Marks)
b) The Students will also be required to read individual sentences, rhymes,poems, newspaper headings, proverbs (use of) minimal pairs etc… ( 5 Marks)
NOTE: While reading, the students will be assessed based on theirperformance in
The examiner needs to have as many passages / exercises as required,proportionate to the number of batches. The passage / exercises will be thesame one to all the students of a particular batch. But it should not berepeated for other batches, there should be different passages / exercises fordifferent batches.
2. SPEAKING ( 15 Marks )
a) Introducing one self / Introducing others and all the other topics given in thesyllabus 5 Marks.
b) Short speech on simple topics on simpler themes for about 2 minutes – 5Marks.
c) Assessing the performance of the students on any of the topics given in thesyllabus in sub division V under Speaking skills. – 5 Marks.
NOTE: The topics identified in the syllabus for Presentation (Speaking skills)need to be written individually one by one by the examiners in separatepapers or in separate cards.
The students will be allowed to choose a topic through lot system. They areexpected to speak on the topic chosen by them for at least 2 minutes.The selection of the topics is left to the discretion of the examiner.
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NOTE: Reading and Speaking:
For assessing the performance of the students in Reading and Speakingskills in the End Examination, each batch of students may be divided into twogroups (if there are 30 students in a batch, they may be divided into 15 + 15)and both groups may be assessed simultaneously, one group by the externalexaminer (for Reading skills) and another by the internal examiner (forSpeaking skills) and then vice versa.This process will enable the examiners to complete the practical on time i.e.,in 3 Hrs. duration.
GROUP C
PROJECT REPORT WRITING ( 10 Marks )
The students will be expected to submit an outline of a Project Reportrelevant to their branches of study in a separate folder and this will beassessed at the time of End Examination and marks will be awardedaccordingly.
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PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR
QUESTION BANK
1) What do we understand by ethics?2) What are the universally accepted ethical principles?3) What is meant by engineering ethics?4) What is the need for engineering ethics?5) Define work ethics.6) What is integrity?7) ‘Commitment’ – what does it mean?8) What do you mean by empathy?9) What is professional ethics?10) What is the similarity between ethics and morals?11) What are the responsibilities of engineers?12) What are the rights of the engineers?13) What are codes of conduct?14) Explain briefly the importance of ethics in engineering profession.15) How can an engineer orient himself towards his ethical responsibilities?16) What are the priorities of an engineer in a situation wherein which conflicting
values are involved?17) How can an engineer implement ethics of his profession in a multi-
cultural/multi-national environment?18) What are the professional obligations of an engineer?19) What should be the ethics that an engineer should adhere to in both pre and
post employment scenarios?20) What is the ethical way of handling retrenchment?21) What are the various aspects of empathy?22) What are the salient features of commitment?23) What is team-work?24) What do you mean by profession and professionalism?25) What is meant by accountability?26) What is environmental ethics?27) What is computer ethics?28) Define the term ‘morals’.29) What do you mean by ‘values’?30) What are the main qualities of work ethics?31) What is altruism?32) What is sharing?33) What is caring?34) What is honesty?35) What is courage?36) What is meant by valuing time?37) What is co-operation?38) What are the objectives of co-operation?39) What is meant by commitment?40) In what way the effective communication skills shape the careers of an
engineer?41) What is self-confidence?42) What is morality and etiquette?
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43) What are the different models of engineering ethics?44) What are the most fundamental moral principles?45) What are the moral responsibilities of an employee towards his employer?46) What are the moral responsibilities of an employer towards his employees?47) What are the moral responsibilities of an organization towards community?48) What are the advantages of team-work?49) What is loyalty?50) What do you mean by professional rights?
Example Questions for Writing Skill
Staff Member may prepare similar type of questions for Class works &Examinations
WRITING
1. Your friend has asked for your advice for buying a birthday present. Write aletter to him/her suggesting which points he\she one should keep in mind likeinterest, age, need etc. while buying a birthday present. You are Shanty /Shantaof 1048 D, Gulabi Bagh, Delhi.
2. Children like to spend their pocket money on their favourite food items like chips,kurkures, hot dog, pizza and cold drinks. But they don’t know that these thingscause harm to their health. Write a paragraph describing the harmful effects offast and junk food. Mention the health and other related problems caused by itin about 50 words.
3. You have to take part in a debate on the theme ‘Examinations affect Teachingand Learning in schools’ Write down your arguments in favour or against themotion in about 125 to 150 words
4. Recently you attended a fair of Eco clubs at Bal Bhawan where the students fromdifferent schools displayed eco friendly materials and ways to protect our earththrough different models and charts. Write a report in about the fair in about 50-60 words.
5. Your cousin is a brilliant student but he is not keeping good health because heavoids homemade food and is very fond of eating outside. Write a letter tellinghim/her about the harmful effects of junk food and advising him/her how tomaintain good health in not more than 100 words. You are Arpil/Arpita of C-8Lawrence Road, Delhi.
6. Write a letter to the Principal of your school requesting him/her to introduce interhouse activities like quiz programmes, debates, recitation, essay-writing,painting and sports explaining how it may be beneficial for all-rounddevelopment of their personality. You are Vineet/Vineeta, the head boy/girl ofNew Modern School, Amritsar.
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7. You don’t approve of the ways of people as they waste a lot of water in differentactivities. Even the taps in schools are not closed properly, thereby, wasting thevaluable water due to negligence and carelessness. You wish to spreadawareness among students about it. Write down your views appealing studentsof your school to conserve water and to save it for future in an article for schoolmagazine in about 50-60 words.
8. You recently visited the ‘World Book Fair’ organized near your Locality and foundit quite an enriching experience. Write a report in about 50-60 words so as toencourage other students to visit it.
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ENGLISH COMMUNICATION PRACTICAL(Common to all branches)
MODEL QUESTION PAPER
TIME : 3 Hrs Max.Marks : 100GROUP A
Answer any ten of the following:- (10 x 2 = 20)I 1) What is teamwork?
2) ‘Commitment’ – What does it mean?3) What is code of conduct?4) How can an engineer orient himself towards his ethical responsibilities?5) What are the professional obligations of an engineer?6) What is the ethical way of handling retrenchment?7) What are the rights of the engineers?8) What is environmental ethics?9) What is sharing?10) What are the objectives of co-operation?11) What is morality and etiquette?12) What is loyalty?13) What are the moral responsibilities of an employee towards his employer?14) What do you mean by professional rights?15) What is altruism?
II ( 2 x 5 = 10)1) Imagine you are applying for a job. Write a resume for the same.2) Religious extremism, matter of concern : PM
III ( 2 x 5 = 10)1) A short story to be played back (audio cassette).2) A face to face communication to be played back (visual/audio)
GROUP BI ( 2 x 5 = 10)
1) Read the following passage aloud -A passage with tricky sounds to be given.
2) Read the following aloud -A conversational passage to be given.
II ( 3 x 5 = 15)1) Introduce yourself2) Short speech - A religious fair3) Any one of the topics given in the syllabus in sub-division v under speaking
skills
GROUP C10
Project Report – writing
The students will be expected to submit an outline of a Project Reportrelevant to their branches of study in a separate folder and this will be assessed at thetime of End Examination.
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ENGLISH COMMUNICATION PRACTICALAllocation & Statement of Marks
Duration : 3 Hrs. Max. Marks : 100
Sl.No.
Reg.No. Name of the Candidate
Communication Lab.Internal
AssessmentTotal
GROUP A GROUP B GROUP C
PE & OB Writing Listening Reading SpeakingProjectReportWriting
Record
Attendance
(20) (10) (10) (10) (15) (10) (20) (5) (100)
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12073 REFIGERATION AND AIR CONDITIONING LABORATORY
6 Hrs/Week 16 Weeks /SemTotal Hrs : 96
OBJECTIVES: Identify the various tools used in R & AC. Demonstrate the construction and working of window air conditioner Demonstrate the construction and working of split type air conditioner. Set parameters for comfortable operation of an air conditioner. Determine the COP of an air conditioner. Determine the capacity of a window air conditioner. Describe the wiring of refrigerator and coolers. Perform servicing on air conditioning system.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12073-
Refrigerationand Air
conditioningLaboratory
Hours/Week
Hours/Semester Assessment Marks
6 96Internal Board Exam Total
25 75 100
1. BASIC REFRIGERATION WORKSHOP OPERATION:
(a) Copper tubing-To study the various sizes of copper tubing.-To study the various tools used for operations.-To become familiar with various operations on copper tubing –Flaring, swaging.
(b) Soldering methods used in R& A.C
2. TO STUDY THE CONSTRUCTION FEATURES OF THE FOLLOWING :
(a) Domestic refrigerators (b) Water coolers (c) Window Air Conditioner(d) Split type air conditioner
3. PROPER METHODS OF SETTING AND ADJUSTING OF
(a) Thermostats(b) Low pressure and high pressure cut-outs(c) Thermostatic expansion valve(d) Automatic expansion valve
4. TEST PROCEDURES
1. To determine the refrigerating effect, C.O.P and the compressor capacity of a open typesystem with a. Thermostatic expansion valve b. Capillary tubec. Automatic expansion valve
2. To determine the C.O.P of sealed system by using electrical measurements3. To determine the capacity of a window air conditioner.4. To determine the efficiency of a cooling tower.5. Wiring of refrigerator, water cooler, desert cooler, room air conditioner - packaged air
conditioner, panel board etc.
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(a) SERVICE PROCEDURES
i. To change refrigerant into service cylinder from storage cylinder.ii. To evaluate the entire systemiii. To Pump down the systemiv. To Purge air from the systemv. To locate the leaks in a system.vi. To charge the systemvii. To check the oil level in the compressor.viii. Tracing the common faults in R& A.C units and their remedies.
SCHEME OF EXAMINATION:
One Question from Test Procedure : 50 marksOne Question from Service Procedure : 10 marksOne Question from Setting and adjusting methods : 10 marksviva - voce : 05 marks
After Completing this practical, the students will have practical Knowledge in Linear Measurement Angular Measurement Flow Measurement Dismantling and Assembly of various machine tools Dismantling and assembly of various motors
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations
12074 metrology,machine tool
maintenance &testing laboratory
Hours/Wee
k
Hours/Semest
er
Assessment Marks
6 96
Internal Board Exam Total
25 75 100
METROLOGY
Syllabus:
1. Introduction to linear measurement2. Introduction to angular measurement3. Introduction to surface measurements4. Linear Measuring Inurnments – Vernier Caliper, Micrometer, Inside Micrometer, Vernier
Height gauge, Depth Gauge and Slip Gauge.5. Angular Measuring Instruments – Universal Bevel Protractor, Sine Bar.6. comparator- Mechanical comparators and Pneumatic comparators.
Exercises:
I. Linear Measurements:
1. Determination of the thickness of ground MS flat to an accuracy of 0.02mm using verniercaliper.
2. Determination of the diameter and length of a turned cylindrical (turned in lable exercise)to an accuracy of 0.02mm using vernier caliper.
3. Determination of the inside diameter of a bush component to an accuracy off 0.02 usingvernier caliper.
4. Determination of diameter of a cylindrical component to an accuracy 0f 0.01mm usingmicrometer and check the result with digital micrometer
5. Determination of inside diameter of the bore of a bush cylindrical component to anaccuracy of 0.01mm using inside micrometer.
6. Determine the heights of gauge blocks or parallel bars to accuracy of 0.02mm usingvernier height gauge and check the result with digital vernier height gauge.
7. Determine the depth of a blind bore component to an accuracy of 0.02mm using vernierdepth gauge.
8. Determine the thickness of ground MS plates using slip gauges
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I. Angular Measurements:
9. Determination of angle of v-blocks, dovetails in mechanical components using universalbevel protractor.
10. Determination of angle of machined surfaces of components using sine bar with slipgauges.
11. Measurement of V-Thread dimensions.12. Measurement of spur gear tooth dimensions.
III. MACHINE TOOL MAINTENANCE & TESTING
1. Dismantling and assembly of tailstock of lathe2. Dismantling and assembly of three jaw chuck3. Dismantling and assembly of four jaw chuck4. Dismantling and assembly of Bench vice5. Dismantling and assembly of D C Motor6. Dismantling and assembly of A.C. Induction Motor7. Dismantling and assembly of Hydraulic cylinders8. Dismantling and assembly of Directional control value9. Testing of lathe10. Testing of Horizontal milling machine11. Testing of Shaping machine12. Testing of Tool and Cutter grinder13. Testing of Pillar type drilling machine14. Testing of Radial Drilling machine15. Testing of Planning machine
SCHEME OF EXAMINATION:
Linear measurement/ Angular measurement (any one by lot) : 20 marksMachine Tool maintenance and testing : 50 marksViva-voce : 05 marks
Total : 75 marks
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12056 WORK SHOP – III (Slotting, Planning, Milling, Grinding & CNC Machines)
6 Hrs/Week 16 Weeks /Sem.Total Hrs : 96
OBJECTIVES:
Identify a planning machine and its parts. Identify a slotting machine and its parts. Identify a milling machine and its parts. Identify a cylindrical grinder, surface grinder and tool and cutter grinder. Identify the tools and instruments. Handle the different types of work holding devices Set the tools in planning and slotting. Machine a component using different machine tools. Calculate the indexing for a work Operate turret and capstan lathe for machining. Write CNC part program Operate CNC Lathe and CNC milling machine.
1. Introduction to planning machine and its parts.2. Introduction to slotting machine and its parts.3. Introduction to milling machine and its parts.4. Introduction to grinding machine and its parts.5. Introduction to turret and capstan lathe.6. Introduction to work holding devices.7. Types of tools used in planning and slotting machines.8. Types of cutter used in milling machine.9. Types of grinding wheels used in grinding machines.10. Types of tools used in turret and capstan lathes.11. Setting of work, tools and cutters in planning, slotting, milling and grinding machines.12. Operation performed in planning, slotting, milling and grinding machines.13. Operation of planning, slotting, milling, grinding, capstan and turret machines.
14.List of Experiments that can be done XLTURN Machinea) Programs using CAM software.b) Step turning operation using G00, G01, & G90 CYCLE.c) Taper turning operation using G00, G01, & G94 CYCLE.
15. List of Experiments that can be done XLMILL Machinea) Programs using CAM software.b) Sub Programming Concepts.c) Contour/Profile Milling Machine using G00,G01,G02 & G03 CODES.
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CNC LATHE WITH BUILT IN CONTROLLER AND MONITORCNC MILL /MACHINING CENTRE WITH ATC IN BUILT CONTROLLER & MONITOR
Specification of CNC Lathe
SCHEME OF EXAMINATION:
CNC Turning/ Mil l ing (by lot) : 30 marksSlott ing and Planning/Mil l ing and Grinding (by lot) : 40 marksViva-Voce : 05 marks
Total : 75 marks
Note: Dimensions of the component may be changed depending upon the availability of standard
dimensioned material without omitting any operations.
Machine SpecificationTurning Length in chuck:80-120mmTurning Diameter 32 mmDistance between center: 200-250mm
X&Z TravelX axis Travel: 70mm -90mmZ axis Travel :150mm- 200mmPositioning Accuracy: 0.010mmRepeatability: 0.005mmInput Resolution: 0.001mmDistance between Centre- 210mmRapid Traverse: 1.2m/minSpindle Speed: 150- 3000rpmSpindle Power: 0.750- 1.2kwSpindle nose taper: MT3Chuck size: 100mm6/8 Station Programmable Indexing Tool Post or Linear ToolingBed Type: Slant bed 45
1.Control Specifications:Built in Industrial type control with 8 inches colour monitorClosed loop control with Servo Motors(100w)Spindle Motor with encoderOperator Panel with following on off.Switch Spindle forward,reverse,switches MPG, Feed & Speed override potentiometers.Built in PLC with Parameter for functions.
2. Program features:Essential:G&M codes as per Fanuc Oi Turning Milling ControlParametric Programming
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Enclosure : Sketches for Exercises
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96
DRILLING HOLES IN RADIAL DRILLING MACHINE.MAKING INTERNAL KEYWAY ANDMACHINING AN EXTERNAL PROFILE.
SLOTTING:
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GRINDING A FLAT SURFACE IN SURFACE GRINDER
MATERIAL: 75X75X12mm
A - TOP RAKE ANGLEB - LIP ANGLEC - FRONT CLEARANCE ANGLED - SIDE RAKE ANGLEE - END CLEARANCE ANGLEF - SIDE CUTTING EDGE ANGLEG - END CUTTING EDGE ANGLEH - NOSE ANGLE
1&6 - FACE2 - SHANK3 - SIDE FLANK4 - END FLANK5 - BASE6 - END CUTTING EDGE7 - NOSE8 - SIDE CUTTING EDGE
9 - NOSE RADIUS
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12061 INDUSTRIAL ENGINEERING AND MANAGEMENT
6 Hrs/Week 16 Weeks/Sem.Total Hrs : 96
OBJECTIVES:
Explain the different types of layout and compare them. Appreciate the safety aspects and its impacts on an organization. Compare different productivity improvement technique. Explain different work measurement techniques. Estimate standard time for a job. Explain production planning and control and its functions. Study the role of PPC as a tool for cost control. Prepare process control charts. Explain the principles of management and function of management. Compare different organizational structure. Explain the selection and training of staff. Analyse Inventory control system and the tools used in stock control. Familiarize different types of companies and their financial aspects.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations
12061Industrial
EngineeringAnd
Management
Hours/week Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
UNIT TOPIC TIME ( Hours )I. Plant Engineering and Plant safety 18II. Work study, Method study and Work
measurement18
III. Production planning and quality control 18IV. Principles of Management and Personnel
Management18
V. Financial Management and MaterialManagement
18
Revision Test 6TOTAL 96
UNIT – I : PLANT ENGINEERING AND PLANT SAFETY 18hrs
Plant Engineering : Plant – Selection of site of industry – Plant layout – Principles of good layout –types – process, product and fixed position – techniques to improve layout – Principles of materialhandling equipment – Plant maintenance – importance – Break down maintenance, preventivemaintenance and scheduled maintenance.
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Plant Safety: Importance – accident – cost and causes of accident – accident proneness – Planningfor accident prevention – Safety laws and regulations – Indian factories act 1948 and provision –Industrial disputes – settlement of industrial disputes.
UNIT – II : WORK STUDY, METHOD STUDY AND WORK MEASUREMENT 18hrs
Work Study: Productivity – Standard of living – method of improving productivity – Objectives –Importance of good working conditions.Method Study: Definition – Objectives – Selection of a job for method study – Basic procedure forconduct of method study – Tools used – Operation process chart, Flow process chart, two handedprocess chart, Man machine chart, String diagram and flow diagram.
Work Measurement: Definition – Basic procedure in making a time study – Employees rating factor– Application of time allowances – Rest, Personal, Process, Special and Policy allowances –Calculation of standard time – Problems – Basic concept of production study – Techniques of workmeasurement.
UNIT – III : PRODUCTION PLANNING AND QUALITY CONTROL 18hrs
Production Planning and Control: Introduction – Major functions of production planning and control– Pre planning – Methods of fore casting – Routing and scheduling – Dispatching and controlling –Critical path method (CPM) No problems. Production – types – Characteristics – Economic BatchQuantity (EBQ) – Principles of product and process planning – make or buy decision – problems.Quality Control: Definition – Objectives – Types of inspection – First piece, Floor and centralizedinspection – Advantages and disadvantages. Quality control – Statistical quality control – Types ofmeasurements – Method of variables – Method of attributes – Uses of X, R, p and c charts –Operating Characteristics curve (O.C curve) – Sampling inspection – Single and double samplingplan.
UNIT – IV : PRINCIPLES OF MANAGEMENT AND PERSONNEL MANAGEMENT 18hrs
Principles of Management: Definition of management – Administration – Organization – F. W.Taylor’s and Henry Fayol’s Principles of Management – Functions of Manager – Types oforganization – Line, Staff, Taylor’s Pure functional types – Line and staff and committee type –Directing – Leadership – Styles of Leadership – Qualities of a good leader – Motivation – Positive andnegative motivation – Just in time – Total Quality Management(TQM) – Quality circle – Zero defectconcept – Management Information Systems – Ethics – Professional ethics.Personnel Management: Responsibility of human resource management – Selection procedure –Training of workers – Apprentice training – On the job training and vestibule school training – Jobevaluation and merit rating – objectives and importance – wages and salary administration –Components of wages – Wage fixation – Type of wage payment – Halsey’s 50% plan, Rowan’s planand Emerson’s efficiency plan – Problems.
UNIT – V : FINANCIAL MANAGEMENT AND MATERIAL MANAGEMENT 18hrs
Financial Management: Fixed and working capital – Resources of capital – Shares preference andequity shares – debentures – Type of debentures – Public deposits, Factory costing – Direct cost –Indirect cost – Factory overhead – Selling price of a product – Profit – Problems. Depreciation –Causes – Methods – Straight line, Sinking fund and percentage on diminishing value method –Problems.Material Management: Objectives of good stock control system – ABC analysis of inventory –Procurement and consumption cycle – Economic order quality problems – Supply chain management– Introduction – Purchasing procedure – Store keeping – Bin card.
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Revision and Test 6Hrs
Text Book:
1. O. P. Khanna, Industrial Engineering and Management, Revised Edition – 2004, Dhanpat RaiPublications (P) Ltd., 67/4 Madras House, Daryaganj, New Delhi 110 002.
2.T. R. Banga & S. C. Sharma, Engineering Economics and Management, Edn. 2 - 2001, publishedby McGraw Hill, New Delhi.
Reference Books:
1.Heinz Weihrich,Harold Koontz, Management, A global perspective, 10th edition ,McGraw Hillinternational edition 1994.2. Joseph L.Massie, Essentials of Management, 4th Edition, Prentice-Hall of India, New Delhi 2004.
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12061 INDUSTRIAL ENGINEERING AND MANAGEMENTMODEL QUESTION PAPER – I
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. State the various methods of plant maintenance?2. What is industrial dispute?3. Define Work Measurement.4. State the allowances as applied to stop watch study?5. Explain the term ‘Routing’.6. State the different techniques of forecasting?7. Define ‘Management’8. What is merit rating?9. What is the advantage of equity share over debentures?10. What is the purpose of finding EOQ?
PART –B Answer all the questions 3x5=15
11.Explain briefly Breakdown maintenance.12.Briefly explain any three methods of improving productivity.13.Differentiate inspection & quality control.14.State and briefly explain the various components of Wages.15.What are the resources of fixed capital. Briefly explain.
PART –C Answer any one question from each unit 10x5=50
16. 1. What are the different types of plant layout? Explain any two with neat sketches. (10)OR
2. State the important Provisions of Factories Act, 1948 governing safety & health of workers.(10)
17. 1. With a neat sketch, explain Man type flow process chart. (10)OR
2. Write short notes on the following:-(i) Ratio delay study (5)(ii) Analytical estimation (5)
18. 1. What is forecasting? Explain the different techniques of forecasting. (10)OR
2. Write short notes on (i) Double sampling plan (5)
(ii) OC curve for a simple plan (5)
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19. 1.A worker completes a job in 6 hrs. The allowed standard time for the job is 8 hrs. His Wagerate is Rs.5 per hour. Calculate the total earnings of the worker under the following systemof payment
(i) Halsey’s 50% plan (5)(ii) Rowan’s plan (5)
OR2. State the principles of management as enumerated by Henry Fayol.
Explain any eight of them. (10)20. 1. Explain by means of a block diagram how the selling price of a product is arrived at. (10)
OR2. Explain how total cost of inventory can be efficiently controlled by “ABC Analysis”
technique. (10)
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12061 INDUSTRIAL ENGINEERING AND MANAGEMENTMODEL QUESTION PAPER – II
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice. Each carries ten
marks.
PART –A Answer all the questions 1x10=10
1. What is collective bargaining?2. Give any two techniques to improve plant layout3. Define Method study.4. Define the term ‘Productivity’?5. State the different types of production.6. What is sampling inspection?7. State any two qualities of a good Leadership.8. Define ‘Quality Circle’.9. Give two examples for inventory carrying cost.10. What is working capital?
PART –B Answer all the questions 3x5=15
11. What is accident proneness?12. Write down any three objectives of method study13. State any three advantages of sampling inspection14. Write down any three functions of human resource management15. Explain the various resources of fixed capital
PART –C Answer any one question from each unit 10x5=50
16. 1. Explain the various factors that are considered for the selection of a site for plant. (10)OR
2. Write short notes on the following:-(i) Collective bargaining (4)(ii) Mediation and Arbitration (6)
17. 1. What is operation process chart? Explain with an example. State guidelines for preparingthe chart? OR (10)
2. Write short notes on(i) Production study (5)(ii) Synthesis from standard data (5)
18. 1. What is production planning & control? Explain the main function. (10)OR
2. (i) Explain Single Sampling plan (5)(ii) Compare PPC with nervous system of human body (5)
19. 1. Discuss the recruitment and selection procedure done by human resource management.OR (10)
2. Explain the functional organization advanced by Taylor using an Organisation chart.State its merits and demerits. (10)
20. 1. Write short notes on(i) Receiving and issuing of material (6)
(ii) Bin cards (4)OR
2. Explain the procurement and consumption cycle of stock control system. (10)
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12062 COMPUTER AIDED DESIGN AND MANUFACTURING6 Hrs/Week 16 Weeks /Sem.
Total Hrs : 96OBJECTIVES:
Define CAD and list stages and benefits of CAD Explain CAD hardware and software Appreciate the uses of computer networking Define CAM and list its functions Explain CAPP, its structure and types Describe MRP and MRP-II, JIT Describe concept of rapid proto typing Differentiate between sequential engineering and concurrent engineering Compare NC, CNC and DNC Explain turning centers and machining centers and CNC EDM machines Describe coordinate measuring machines Explain spindle drives and slide ways Explain ATC Explain different feedback devices. Prepare NC part programs using G code and M code Describe conversational programming and APT programming Explain the concept of group technology, FMS and CIM Describe MICLASS and OPITZ systems Describe AGV and robots.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12062-
Computer AidedDesign and
Manufacturing
Hours/Week
Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
Unit Topic TIME (Hrs)I Computer Aided Design and Geometric Modeling 18II Computer Aided Manufacturing 18III CNC Machines 18IV CNC Components and Part Programming 18V GT-FMS-CIM-AGV and Robotics 18
Revision and Test 6Total 96
UNIT – I COMPUTER AIDED DESIGN AND GEOMETRIC MODELING 18 HrsIntroduction – CAD definition – Shigley’s design process – CAD activities – benefits of CAD – CADhardware : Input / Output devices – CRT – raster scan & direct view storage tube – LCD, plasmapanel, mouse, digitizer, image scanner, drum plotter, flat bed plotter, laser printer – secondarystorage devices : hard disks, floppy disks, CD, DVD, flash memory.Types of CAD system: PC based CAD system – workstation based CAD system – graphicsworkstation – configuration and typical specification – CAD software packages – AutoCAM –computer networking: purposes – topology – types – OSI networking standards – protocols(description only).Geometric modeling techniques: wire frame, surface, solid modeling – graphics standards: Need,GKS – IGES – DXF.Introduction to finite element methods – procedure of finite element analysis (brief description only).
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UNIT II – COMPUTER AIDED MANUFACTURING 18 Hrs
CAM definition – functions of CAM – benefits of CAM – integrated CAD/CAM organization – processplanning – master data – structure of a typical CAPP – types of CAPP : variant type, generative type– advantages of CAPP - aggregate production planning – Master Production Schedule (MPS) –capacity planning – Materials Requirement Planning (MRP) – introduction to enterprises resourcesplanning –Manufacturing Resources Planning (MRP-II) – just in time manufacturing philosophy – costinvolved in design changes – concept of Design for Excellence (DFX) – guide lines of Design forManufacture / Assembly (DFM/A).Product Development Cycle – sequential engineering – concurrent engineering – rapid proto typing:concept and applications – 3D printing.
UNIT-III CNC MACHINES 18 Hrs
Numerical control – definition – components of NC systems – development of NC – DNC – CNC andadaptive control systems – working principle of a CNC system – distinguishing features of CNCmachines - advantage of CNC machines – difference between NC and CNC – types of turning centre:horizontal, vertical – types of machining centers: horizontal spindle, vertical spindle, universalmachines – machine axis conventions – design considerations of NC machine tools.CNC EDM machine – Coordinate measuring machines: construction, working principles andspecifications – maintenance of CNC machines.
UNIT-IV CNC COMPONENTS AND PART PROGRAMMING 18 Hrs
Drives: spindle drive – hydraulic systems – direct-current motors – stepping motors – servo motors –AC drive spindles - slide ways – linear motion bearings – recirculation ball screw – ATC – toolmagazine - feedback devices: encoders – linear and rotary transducers – in-process probing.NC part programming – manual programming – tape format : sequence number, preparatoryfunctions and G codes, miscellaneous functions and M codes – CNC program procedure –coordinate system – types of motion control: point-to-point, paraxial and contouring - NCdimensioning – reference points – machine zero, work zero, tool zero and tool offsets.Part Program – tool information – speed – feed data – interpolation – macro – subroutines – cannedcycles – mirror images – thread cutting – sample programs for lathe and milling – generating CNCcodes from CAD models – post processing – conversational programming – APT programming.
UNIT- V GT-FMS-CIM-AGV AND ROBOTICS 18 Hrs
Group Technology(GT) – concept of part family – parts classification and coding – coding structure –MICLASS – OPITZ – benefits of GT.FMS & CIM – introduction to FMS – types of manufacturing - FMS components – FMS layouts –types of FMS : flexible manufacturing cell – flexible turning cell – flexible transfer line – flexiblemachine systems – benefits of FMS - concept of CIM – historical background –- CIM hardware – CIMsoftware – CIM wheel - introduction to intelligent manufacturing system – virtual machining.Integrated material handling – AGV: working principle and benefits – Automatic Storage and RetrievalSystems (ASRS).ROBOT – definition – robot anatomy and classifications – robot configurations – industrialapplications: characteristics, material transfer, machine loading, welding, spray coating, assemblyand inspection
Revision and Test 6Hrs
Text Books:
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1. CAD/CAM/CIM, R.Radhakrishnan, S.Subramanian, V.Raju, 2nd, 2003, New Age International Pvt.Ltd.
2. CAD/CAM, Mikell P.Groover, Emory Zimmers Jr. Indian Reprint Oct 1993, Prantice Hall of IndiaPvt., Ltd.
1. Dr.P.N.Rao, CAD/CAM Principles and Applications, 2002, Tata Mc Graw Hill Publishing CompanyLtd.
2. Ibrahim Zeid, Mastering CAD/CAM, Special Indian Edition 2007, Tata McGraw-Hill PublishingCompany Ltd., New Delhi.
3. Mikell P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing, 2nd
Edition, Reprint 2002, Pearson Education Asia.4. Yoram Koren, Computer control of manufacturing systems, International Edition 1983, McGraw
Hill Book Co
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12062 COMPUTER AIDED DESIGN AND MANUFACTURINGMODEL QUESTION PAPER – I
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice. Each carries ten marks.
PART –A Answer all the questions 1x10=101. Expand ADSL.2. What is a bus?3. What is the documented form of processing sequence for producing parts called?4. What is machine loading?5. What is the expansion of btr?6. What are macros?7. How does rotary encoder works?8. What is the g code for tool nose radius compensation left?9. Name the device used to regulate work cell components.10. Write the general form of an apt geometry statement.
PART-B Answer all the questions 5x3=15
11. Define cad. What are the essentials of CAD?12. Write short notes on intelligent manufacturing system.13. Explain how cnc machines are integrated with CIM environment.14. What are the data required for manual part programming?15. State the benefits and applications of FMS.
PART-C Answer any one question from each unit 10x5=5016 1. (a)What are the various types of modelling techniques? (5)
(b) Explain in detail surface modelling technique? (5)OR
2. Explain any three output devices with simple sketches (10)
17. 1. What is MRP? explain how it works? (10)OR
2. Explain in detail the operation of typical CAPP system (10)
18. 1. (a) What is CMM? (4)(b) Explain the working of CMM with neat sketch. (6)
OR2. (a) Explain in detail how cnc drilling machine works. (5)
(b) What are the benefits of adaptive control? (5)
19. 1. (a) Describe any five g codes with meaning (6)(b) Explain fixed zero,floating zero (4)
OR2. (a) What are the requirements of spindle drives? (5)
(b) Explain tool magazine and its requirements (5)
20. 1. (a) Explain the term group technology. (5)(b) What are the benefits of group technology? (5)
OR2. (a) What are the components of agv? (4)
(b) Explain vehicle guidance and routing system in AGV (6)
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12062 COMPUTER AIDED DESIGN AND MANUFACTURINGMODEL QUESTION PAPER – II
DURATION : 3 HRS. MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. What is the tiny granular powder applied to drum in laser printer called?2. Define locator in GKS.3. Name any one approach used in CAPP.4. What is the other name for inference engine?5. What is arcnet?6. What is the main objective of adaptive control?7. What is called as home position?8. N050 M06 T0616. What does this tell us?9. Define robot.10. What is a key machine?
PART-B Answer all the questions 5x3=1511. What is Lan? What are the types of Lan?12. Write short notes on capacity planning.13. Explain any one type of cnc grinding.14. Explain about conversational programming.15. Describe common robot configurations.
PART-C Answer any one question from each unit 10x5=5016. 1. (a) Differentiate between b-rep and c-rep. (5)
(b) Write short notes on interactive computer graphics (5)OR
2. Discuss solid modelling with an example.state its merits and demerits (10)
17. 1. (a) Explain rapid prototyping (5)(b) What are the objectives of MPS? (5)
OR2. (a) What is artificial intelligence? (4)
(b) With a line diagram explain the major components of AI system. (6)
18. 1. (a) Briefly explain the maintenance of CNC machines (5)(b) State the various features of turning centres. (5)
OR2. (a) Compare NC systems with CNC systems. (5)
(b) List out the various mechanical structure of CMM (5)
19. 1. What is mirroring in CNC program?. Explain with an example. (10)OR
2. Explain the terms macros, subroutines and canned cycles used in CNC partprogramming.(10)20. 1. What are the three elements of product design? Explain each of them in detail. (10)
OR2. Discuss in detail material handling and storage system in FMS. (10)
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12081 AUTOMOBILE TECHNOLOGY
5 Hrs/Week 16 Weeks /Sem.Total Hrs : 80
OBJECTIVES: Explain about the constructional details of an IC engine including cooling and lubrication
system. Describe fuel feed systems with all devices involved in it (Both for petrol and diesel engines). Explain the construction and functional features of the power transmission systems and
various parts involved in it . Explain the functions of different types of steering and brake systems. Familiarize electrical and electronic equipments used in automobile. Describe the different types of chassis and their functions. Appreciate the techniques for automobile pollution control.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12081- Automobile
TechnologyHours/Week
Hours/Semester
Assessment Marks
5 80Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
Unit Topic TIME (Hrs)I. Automotive Engines 15II. Fuel and Fuel Feed Systems 15
III. Transmission and Power Trains 15IV. Automotive Chassis 15V. Automobile Electrical Equipment and Pollution Control 15
Revision and test 5TOTAL 80
UNIT I AUTOMOTIVE ENGINES 15hrs
Basic engine components-functions, types, materials and construction of-cylinder block-cylinderhead-gaskets-crankcase-oil pan-cylinder liners-comparison of liners-piston-expansion control inpistons-piston rings-types of compression and oil control rings-piston pin- connecting rod-methods ofconnecting piston and connecting rod-crankshaft-fly wheel-cam shaft-methods of cam shaft drivearrangements-valve and valve arrangements-L-I-F-T.Stages of combustion-delay period-variables affecting delay period-combustion chamber-methods ofgenerating air swirl in diesel combustion chamber-types of combustion chamber-merits and demerits.Cooling systems-purpose-methods-air, water and other coolants-pump assisted cooling systems-fan-sensors-radiator types-pressure cap-expansion systems-merits-vented and pressurised-expansiontank-troubles in cooling system-loss of coolant, overheating and overcooling-causes.Lubrication systems-purpose-types of lubricants-properties-additives-service rating of oil-types oflubricating system-types of filters-methods of cylinder and piston lubrication-high pressure systems-oilpumps-troubles in lubrication system-oil leakage, low oil pressure and excessive oil consumption-causes.
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UNIT II FUEL AND FUEL FEED SYSTEMS 15hrs
Requirement of an ideal petrol-octane number-detonation-properties of a good diesel fuel-cetanenumber-diesel knock-methods of controlling diesel knock-fuel additives-alternate fuels for petrol anddiesel engines-benzol, methanol, ethanol, natural gas, LPG, vegetable oils and bio-gas.Layout of fuel feed system of petrol engine-types of fuel feed system-A.C. mechanical fuel pump-S.U.electrical fuel pump-fuel filter-air cleaners-types-carburetion-classification of carburetors-simplecarburetor-carburetor circuits-solex carburetor-construction and operation-DTSI, VTI, CCVTI, PGMFI-petrol injection-MPFI system-necessity-merits and demerits.Layout of diesel fuel feed system-single acting fuel feed pump-injection pumps-construction andworking of distributed type pump, CRDI-fuel injectors-purpose-types-single and multiple-pintle andpintaux-governors-necessity-types of governors-mechanical and pneumatic-fuel filters-primary andsecondary filters-location and importance.
UNIT III TRANSMISSION AND POWER TRAINS 15hrs
General arrangement of power transmission system-arrangement of front engine drive-rear enginerear drive-four wheel drive-applications-clutch-function-components-types-single plate, multiplate wetand dry clutches and diaphragm clutch-fluid coupling-clutch troubles and their causes.Gear box-purpose-various resistance to motion-types of gear boxes-sliding mesh, constant mesh andsynchromesh-floor shift and steering column gear change-mechanical and hydraulic control system-variator-gear box troubles and their causes.Drive line-propeller shaft-universal joint-cross type only-slip joint-final drive-function-types of geararrangement-straight and spiral bevel, hypoid, worm and worm wheel-merits, demerits andapplication-Hotch kiss drive-torque tube drive-radius rod.Differential-purpose-construction and operation- self locking and non slip differential troubles andtheir causes-forces in rear axles-rear axles-semi floating, three quarter floating and full floating axle-axle housing-types.
UNIT IV AUTOMOTIVE CHASSIS 15hrs
Front axle-types-stub axle-elliot and reverse elliot-lemoine and lemoine inverted-steering system-Ackermann principle of steering-wheel alignment-factors-camber, caster, king pin inclination, Toe inand Toe out on turns-steering linkages-steering gears-cam and double roller, recirculating ball type,rack and pinion-steering troubles and causes- power steering-necessity-types-layout of any one type.Suspension system-functions-types of springs-leaf, coil and Torsion bar-front suspension systems-independent front suspension-merits and demerits-types-rear end suspension-air suspension (briefdescription only)-shock absorber-purpose-telescopic type-construction and working.Brake system-functions- classification of brakes-drum brakes-leading shoe and trailing shoe-selfenergizing action-hydraulic brake-brake bleeding-brake shoe adjustment mechanism-air assistedhydraulic brakes-air brake-layout, functions of each components and application only-disc brakes-construction and working-comparism of disc and drum type-brake troubles and their causes-antilockbrake system.Wheels-disc wheels, wire wheel, spilt wheel and light alloy cast or forged wheels-brief description andapplications-tyres-functions-construction of tyres-cross and radial ply tyres, tubeless tyres-comparison-properties of tyres-tyre wear and tyre service.
UNIT V AUTOMOBILE ELECTRICAL EQUIPMENT AND POLLUTION CONTROL 15hrs
Battery-lead acid battery-nickel alkaline battery-construction-battery rating-charging-testing-startingsystem-circuit construction and operation of starter motor-starting motor drives-over running clutchand Bendix drive-construction and operation-solenoid switch-charging system-circuit-alternatorconstruction and operation-regulators-Dynamo.Ignition system-types-battery coil ignition system-circuit-high-tension magneto-principle of operationof flywheel magneto-electronic ignition-ignition system troubles and remedies.Lighting system- circuit-head light-aiming adjustment-sealed beam head lights-fluorescent lamp-trafficindicator-directional signal circuits-horn circuits-wind screen wiper.
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Pollution-pollution control techniques for petrol and diesel engine emissions-controlling crankcaseemission (PCV)-controlled evaporative emission (VRS, VSS, VRR, ECS and EES)-treatment ofexhaust gas (catalytic converter, EGR).Introduction to automotive electronics, radio-interference-suppressors-audio systems.
Revision and Test 5 Hrs
Text Books:1. Kirpal Singh, “Automotive Engineering”, Vol.I and II, Standard Publishers, 1705-B,
Naisarak, Post Box 1066, New Delhi 110 006 – 2005.2. Banga and Singh, “Automobile Engineering”, Khanna Publishers, New Delhi, 1998.3. Narang. G.B.S., “Automobile Engineering”, Khanna Publishers, New Delhi, 1998.4. Automobile Transmission and Power systems- William.H.Grouse.5. Automobile Electrical Equipments- William.H.Grouse.
Refernce Books:1. Dolan.J.A.,”Motor vehicle technology and practical work”, ELBS, 1978.2. Dr.Giri.N.K,”Automobile Mechanics”, Khanna Publishers, New Delhi, 1998.3. Automotive Mechanics, Edn. 6, McGraw Hill Co., New York.
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12081 AUTOMOBILE TECHNOLOGYMODEL QUESTION PAPER - I
DURATION : 3 HRS. MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. State any one function of piston rings2. Name the two types of commonly used thermostats.3. What is the function and choke value in carburetor.4. Why is governess necessary in diesel engines?5. What is the main advantage of the four wheel drive vehicle?6. What is the purpose of differential?7. Define cawber.8. Name important components of a drum brake9. Enumerate main components of lead-acid battery.
10. Name the areas of automobile emitting pollutants.
PART-B Answer all the questions 3x5=15
11. What are the factors influence the ignition delay periods C.I. Engines12. Draw the neat sketch of A.C. mechanical pump13. Draw the neat sketch of full floating axles14. Explain clearly the requirements of automobiles brakes15. Discuss in detail the requirements of an ignition system of an internal combustion engine.
PART-C Answer any one question from each unit 10x5=50
16. 1. a) Explain detonation with its causes and control. (5)b) Draw and explain the acceleration and starter circuit in solex carburetor (5)
OR2. Explain with neat sketch the pump assisted cooling system. (10)
17. 1. a) Explain the methods of connecting piston and connecting rod (5)b)Draw the distributor fuel injection pump with neat sketch. (5)
OR2. Name the different types of nozzle and state its function. (10)
18 1. Explain the necessity of a differential of an automobile. Discuss in detail the construction andoperation of the differential with sketch.
(10)OR
2. With a simple sketch explain the construction and working of multi-plate clutch. (10)
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19. 1. Discuss in detail the rack and pission type manual steering gear type by means of a simplesketch and discuss its advantages
(10)OR
2. Draw the schematic diagram showing the layout of complete air pressure system of brakesand explain the working of brake valve with the help of a neat diagram.
(10)
20. 1. Explain the construction and operation of a transistor assisted ignition system. (10)OR
2. Show with a help of neat sketch the construction and working of lead-acid battery. (10)
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12081 AUTOMOBILE TECHNOLOGYMODEL QUESTION PAPER - II
DURATION : 3 HRS. MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1. State types of cylinder liners.2. What is the purpose of cooling system.3. What is biogas?4. Mention types of injection nozzles.5. What is the function of clutch?6. List out any two types of universal joint.7. What is dead Axle?8. What is King pin inclination?9. What are the two mostly used type of batteries?10. What is mean by pollution?
PART-B Answer all the questions 3x5=15
11. Explain function of oil rings.12. What is ethanol?13. Draw a sketch of propeller shaft.14. Explain Caster angle.15. Explain working of solenoid switch.
PART-C Answer any one question from each unit 10x5=50
16. 1. a) Explain working of Tubular type radiator. (6)b) Explain dry sub lubrication (4)
OR2. Explain various stages of combustion in diesel engine (10)
17. 1. With neat diagram explain working of mechanical governor (10)
OR2. a) What are the functions of carburetor? (4)
b) With diagram explain A.C fuel pump (6)
18. 1. a)Draw a layout of front engine front drive (5)
b)Explain with sketch working of fluid coupling (5)
OR2. With a neat diagram explain working of differential unit. (10)
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19. 1. Explain with sketch type of front axle (10)OR
2. Explain with sketch working of Recirculating ball type steering gear box. (10)
20. 1. a)Explain starting circuit with solenoids (5)b)Explain major parts of a lead acid battery (5)
OR2. Explain with diagram transistor assistant ignition system. (10)
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12082 MECHATRONICS
5 Hrs/Week 16 Weeks/SemTotal Hrs : 80
OBJECTIVES: Define Mechatronics and state its role in industries. Compare the different types of sensors/transducers Describe the basic actuation systems and their importance. Describe various basic Mechanical and Electrical actuation systems. Explain the various basic pneumatic and hydraulic actuation systems. Construct the basic mechanical system building blocks. Construct a basic electrical system building blocks. Construct a basic fluid system building blocks. Explain the basic system models used in engineering Explain the structure of PLC and its functions. Write PLC program for simple applications. Differentiate traditional versus mechatronics design. Apply Mechatronics design to real life case studies.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12082-
MechatronicsHours/Week Hours/Semester Assessment Marks
5 80Internal Board Exam Total
25 75 100
TOPICS AND ALLOCATION
UNIT TOPIC TIME (Hrs)I Introduction, Sensors & Transducers 15II Actuation Systems (Mechanical, Electrical, Pneumatic &
Hydraulic)15
III Basic System Models, input/output Systems 15IV Programmable Logic Controller (PLC) 15V Design Examples & Advanced Applications in Mechatronics 15
Revision, Test 5Total 80
UNIT-I INTRODUCTION, SENSORS & TRANSDUCERS 15 Hrs
Introduction – Systems – Measurement Systems – Control Systems – Microprocessor BasedControllers Examples – Mechatronics approach.Measurement System terminology – Displacement, Position & Proximity Sensors – Velocity andMotion Sensors – Force Sensors – Fluid Pressure Sensors – Flow Sensors – Liquid Level Sensors –Temperature Sensors – Light Sensors – Selection of Sensors.
UNIT-II ACTUATION SYSTEMS (MECHANICAL, ELECTRICAL, PNEUMATIC &HYDRAULIC) 15 Hrs
Mechanical Actuation Systems – Types of motion – Freedom and constraints – Loading – GearTrains – Pawl & Ratchet – Belt & Chain drive – Bearing – Selection – Ball & Roller bearings –Mechanical aspects of motor selection.Electrical Actuation Systems – Switches & Relays – Solenoids – D.C Motors – A.C.Motors – StepperMotors – Specification and control of stepper motors – Servomotors: D.C Servomotor and A.CServomotor.Pneumatic & Hydraulic Systems – Power supplies – DCV – PCV – Cylinders – Rotary actuators.
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UNIT-III BASIC SYSTEM MODELS, INPUT/OUTPUT SYSTEMS 15 Hrs
Mathematical Model – Introduction to mathematical model - Mechanical System building blocks –Electrical System building blocks – Fluid System building blocks – Thermal System building blocks.System Model – Engg. Systems – Rotational-Translational Systems – Electro-Mechanical System –Hydro-Mechanical System.Interfacing - Input/Output ports - Interface requirements: Buffers, Handshaking, Polling and interrupts,Serial interfacing - Introduction to PIA - Serial communications interface - Example of interfacing of aseven-segment display with a decoder.
Definition – Basic block diagram and structure of PLC – Input/Output processing – PLCProgramming: Ladder diagram, its logic functions, latching and sequencing – PLC mnemonics –Timers, internal relays and counters – Shift registers – Master and jump controls – Data handling –Analog input/output – Selection of PLC.
UNIT-V DESIGN EXAMPLES & ADVANCED APPLICATIONS IN MECHATRONICS 15 Hrs
Design process stages - Traditional Vs Mechatronics designs - Possible design solutions: Timedswitch, Wind-screen wiper motion, Bath room scale - Case studies of mechatronics systems: A pick-and-place robot, Car park barrier, Car engine management system, Automatic Camera andAutomatic Washing Machine only.Sensors for condition monitoring systems of production systems - Examples of monitoring methods:Vibration monitoring, Temperature monitoring, Wear behavior monitoring - Mechatronics control inautomated manufacturing: Monitoring of manufacturing processes, On-line quality monitoring, Model-based systems, Hardware-in-the-loop simulation, Supervisory control in manufacturing inspection,Integration of hetrogeneous systems.
Revision and Test 5Hrs
Text Books:
1. W.Bolton, Mechatronics, 2nd Edition 2001, Pearson Education, New Delhi.2. R.K.Rajput, A Text Book of Mechatronics, 1st Edition 2007, S.Chand & Co. Ltd., New Delhi.
Reference Books:
1. HMT, Mechatronics, 1st Edition 1998, Tata McGraw Hill, New Delhi.2. Devdas Shetty & Kolk, Mechatronics System Design, 1st Reprint, 2001, PWS Publishing Co.,
Boston.3. James H.Harter, Electromechanics, 1st Edition 2003, Prentice-Hall of India, New Delhi.4. M.D.Singh & J.G.Joshi, Mechatronics, 1st Edition 2006, Prentice-Hall of India, New Delhi.
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12082 MECHATRONICSMODEL QUESTION PAPER-I
DURATION : 3 HRS. MAX MARKS:75
NOTE : Answer all the questions from Part-A (1 mark each)Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice.Each carries ten marks.
PART –A Answer all the questions 1x10=10
1) Define Mechatronics2) Define Sensor3) What are all the Mechanical elements?4) Define Actuators.5) Define System Model.6) What is the purpose of dashpot in mathematical model?7) What is the function of Latch?8) What are the features of PLC?9) What is meant by ROBOT?10) Define Embedded System.
PART-B Answer all the questions 3x5=15
11) Draw the diagram of potentiometer sensor.12) What is the Basic Principle of DC Motor?13) Write the difference between parallel and serial Interface.14) Draw the ladder diagram for counter.15) What are the features of supervisory control system?
PART-C Answer any one question from each unit 5x10=50
16) 1. a) What are the parameters to be considered while selecting sensor. (4)b) With a neat diagram explain the working principle of displacement transducer. (6)
OR2. Explain closed loop controlled system with example. (10)
17) 1. Explain the working principle of stepper motor with specification. (10)OR
2. a) Explain the various types of Belt with neat diagram. (5)b) Explain the factors to be considered for motor selection. (5)
18) 1. Describe mathematical model for Thermal System. (10)OR
2. a) Briefly explain three state buffer (5)b) What is the function of peripheral interface adaptor? (5)
19) 1. Draw the ladder diagram for code converter. (10)OR
2. a) Design ladder diagram for timing circuit that switch ON output for 2 second then OFFfor 10 seconds. (5)
b) Cylinder A and B will activate together and cylinder C will activate after 5 secondsdelay. Draw a ladder for the above sequence of operation. (5)
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20) 1. Explain car engine management system with neat diagram. (10)OR
2. a) Explain car park barrier with neat diagram. (5)b) What are the factors to be considered for vibrating monitoring? (5)
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12082 MECHATRONICSMODEL QUESTION PAPER-II
DURATION : 3 HRS. MAX MARKS:75NOTE : Answer all the questions from Part-A (1 mark each)
Answer all the questions from Part-B ( 3 marks each)Answer all the questions in Part – C by either or choice. Each carries ten
marks.
PART –A Answer all the questions 1x10=10
1) Define Control System2) Define accuracy3) Define Mechanism.4) Define Drive.5) What is the purpose of mathematical model?6) What is the mathematical model for spring.7) Define PLC.8) Define Ladder Diagram.9) Mention the sensor that can be used for production system.10) Mention the technique used in Automatic washing machine.
PART-B Answer all the questions 3x5=15
11) Explain briefly about diapharam type fluid pressure sensor.12) Brielfy explain gear train.13) Draw rack and pinion diagram of rotational translation system.14) Draw ladder diagram for 4bit shift operation.15) What is the difference between CAM operated time switch and PLC operated Time switch.
PART-C Answer any one question from each unit 5x10=5016) 1. Explain Engine management system with neat diagram. (10)
OR2. a) Draw the diagram of metal wire and metal foil type strain gauge. (4)
b) Explain bellows and diaphragm type pressure sensor with neat diagram (6)
17) 1. a) Draw the neat diagram of relay . (5)b) Briefly explain solenoid (5)
OR2. Explain the working principle of directional control valves. (10)
18) 1. Explain interfacing a seven Segment display with a decoder with a neat diagram. (10)OR
2. a) Draw the mathematical model of a wheel of a car moving along a road. (5)b) Briefly explain serial communication (5)
19) 1. Draw Internal Architecture of PLC and explain each block. (10)OR
2. a) Design a circuit that can be used to start a motor and then after a delay of 100 secondsStart pump when the motor is switched off there should delay of 10 seconds before thepump is switched off. (5)
b) Briefly explain jump instruction (5)
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20) 1. Explain a pick and place Robot with any one application. (10)OR
2.a) Design a Digital thermometer system which will display temperature between 0º c and99ºc. You might like to consider a solution based on the use of the microprocessor with Ramand ROM chips.
(6)b) Briefly explain steps involved in design process. (4)
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12064 COMPUTER AIDED DESIGN AND MANUFACTURING PRACTICAL
6 Hrs/Week 16 Weeks /Sem.Total Hrs : 96
OBJECTIVES:
Practice on CAD commands for 3D drawings. Draw 3D CAD drawings using solid modeling. Practice on Solid rendering. Differentiate incremental System with absolute system Prepare a part program, edit and execute in CNC lathe. Prepare a part program, edit and execute in CNC milling machine. Produce parts in CNC lathe and milling machine.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12064- ComputerAided design and
1. Predefined 3D objects – converting 2D plan into a 3D model – 3Dmesh – 3Dface - 3Dpoly -creating surfaces – Rulsurf – Revsurf – Tabsurf – Edgesurf – isolines -3DView – viewports –Vpoint – hide – dview – modelspace - paper space.
2. 3D solid primitives - creating region – pedit – extrude – revolve - combining object – union –subtract – intersect – Align – Fillet – chamfer - Advanced 3D editing techniques – align - 3D array–Mirror 3D - Rotate3D.
3. Working with UCS – 3D coordinate system – DDUCS – Plan – UCS icon
4. Solid Rendering – material attaching and detaching – shade with color – slice and sectioning –script – 3D orbit – calculating mass properties
5. Developing LISP program – constructing a list – input/output functions – control structures -arithmetic operations – trigonometric functions – special functions.
3D solid modeling and LISP programming practice (40 Hours)
i) Geneva Mechanismii) Cast Iron Blockiii) Bearing Blockiv) Bushed Bearingv) Gib and Cotter jointvi) Screw Jackvii) Universal Couplingviii) Simple LISP programs for drawing the following: rectangle, circle, concentric rectangles,
concentric circles, changing the colors and line typesix) LISP program for drawing the spur gear given the gear parameters (may be done as a simple
project; not for exam. Reference may be made to the book: Mastering CAD/CAM by IbrahimZeid, Special Indian Ed. 2007., pp91
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Part-2 CAM Practical (38 Hours)
Introductions (8 Hours)
1. Study of CNC lathe, milling2. Study of international standards G-Codes, M-Codes3. Program writing – Turning simulator – Milling simulator, IS practice – commands – menus
Exercise practice (30 Hours)
CNC Lathe
1. Develop a part program for step turning and simulate2. Develop a part program for taper turning and simulate3. Develop a part program for circular interpolation and simulate4. Develop a part program for multiple turning operation and simulate5. Develop a part program for thread cutting, grooving and simulate6. Develop a part program for internal drills, boring and simulate
CNC Milling
1. Develop a part program for grooving and simulate2. Develop a part program for drilling (canned cycle) and simulate3. Develop a part program for mirroring with subroutines and simulate4. Develop a part program for rectangular and circular pocketing and simulate
Model exam / Revision (8 Hours)
Facilities for imparting training:
1. Personal computer (Pentium processor)2. MS Windows OS (Version 2000 or above)3. AutoCAD software (release 2000 or above)4. CNC Lathe and Milling simulation softwares5. Laser jet printer for getting hard copies of student work
SCHEME OF EXAMINATION
Solid modeling (creating model and writing massproperties)
: 40 marks
CNC Program writing and execution : 30 marksViva Voce : 05 marks
Total : 75 marks
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Geneva Mechanism
Cast iron Block
128
Bearing Block
Bushed Bearing
129
Gib and Cotter Joint
Screw Jack
130
Universal Coupling
131
CAM Practicals – Lathe
132
CAM Practical - Milling
133
12083 AUTOMOBILE LABORATORY
6 Hrs/Week 16 Weeks /Sem.Total Hrs : 96
OBJECTIVES:
Identify the various tools and their applications used in Automobile. Dismantle and assemble parts of petrol engine. Dismantle and assemble parts of diesel Engine. Service oil pump and water pump. Service AC fuel pump Service carburetor. Dismantle and assemble fuel injection pump. Dismantle and assemble of power transmission and differential system. Overhauling of starter motor and dynamo. Troubleshoot the Electrical circuit in automobile.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12083-
AutomobileLaboratory
Hours/Week Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
PART A
1. Identification and application of mechanic’s tools.2. Dismantling and assembling of four stroke petrol engine and identification of parts.3. Dismantling & assembling of four stroke Diesel engine and identification of parts.4. Cleaning, inspecting and measuring cylinder bore using cylinder bore dial gauge and suggesting
the next over size.5. Removing decarbonising, inspecting and replacing connecting rods and adjusting the bearings.6. Removing camshaft, replacing timing gears, removing valves, lapping and adjusting valve
clearance.7. Removing, servicing and replacing oil pump and water pump.8. Removing, servicing and replacing of A.C. fuel pump / S.U. electric fuel pump.9. Removing, servicing SOLEX carburetor/ MPFI.11. Dismantling and assembling of inline F.I.P/CRDI12. Dismantling and assembling of injectors.
PART B
1. Removing and replacing of pressure plate and clutch plate, fingers adjustment.2. Dismantling, inspecting and assembling of gear box and finding out the gear ratios.3. Dismantling, assembling and adjusting of steering gearbox. Finding the gear ratio.4. Dismantling and assembling dismantling, inspecting and assembling of final drive and differential
units. Adjusting of backlash5. Trace the automobile electrical system with respect to (i) Horn relay circuit (ii) Wiper circuit.
Explain with neat circuit diagram.6. Trace the automobile electrical system with respect to (i) Battery coil ignition system (ii)
Magneto ignition system.7. Dismantling and overhauling of a starter motor.8. Dismantling and overhauling of a dynamo/alternator.
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9. Test a battery with specific gravity test and charge the battery with constant Ampere/Voltagemethod.
10. Trace the automobile electrical system with respect to starting and charging systems.
SCHEME OF EXAMINATION:
One question from PART A : 30 marksOne question from PART B : 40 marksViva - voce : 05 marks
Identify pneumatic operated single acting cylinder and double acting cylinder. Analyse operation of quick exhaust valve. Analyse the speed control of double acting cylinder. Analyse the operation of hydraulic operated cylinder and motor. Analyse the speed control of hydraulic operated double acting cylinder. Analyse the operation of hydraulic directional control valve. Analyse the operation of logic control circuit used in PLC. Analyse the operation of Timer, Latch, Counter used in PLC.
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12084-
MechatronicsLaboratory
Hours/Week Hours/Semester Assessment Marks
6 96Internal Board Exam Total
25 75 100
A) PNEUMATICS LAB
1. Study of pneumatic system - elements - pressure control valves - directional control valves (DCV)2. Direct operation of a single acting cylinder3. Direct operation of a double acting cylinder.4. Operations of single acting cylinder controlled from two different positions using shuttle valve.5. Operation of a double acting cylinder with quick exhaust valve.6. Speed control of double acting cylinder using metering in and metering out circuit.
B) HYDRAULICS LAB
1. Study of hydraulic system and its elements.2. Direct operation of double acting cylinder.3. Direct operation of hydraulic motor.4. Speed control of double acting cylinder - using metering-in and metering-out control.5. Speed control of hydraulic motor - using metering-in and metering-out control.6. Operation of a double acting cylinder using solenoid operated directional control valve.
C) PLC LAB
1. Study of PLC system and its elements.2. Direct operation of a motor using latch circuit.3. Operation of a motor using AND logic control.4. Operation of a motor using OR logic control.5. On-delay timer control of a motor.6. Off-delay timer control of a motor.
RESOURSES
Pneumatic trainer kit with air compressor. Hydraulic trainer kit with hydraulic power pack Programmable logic controller with electro - pneumatic training kit.
12066 PROJECT WORK, ENTREPRENEURSHIP, ENVIRONMENT & DISASTER MANAGEMENT(PROJECT WORK NORMS AS PER THE LATEST REGULATIONS ONLY)
6 Hrs/Week 16 Weeks /Sem.Total Hrs : 96
SCHEME OF INSTRUCTION AND EXAMINATION
Subject Instruction Examinations12066 -
Project work,Entrepreneurship,
Environment & DisasterManagement
Hours/Week
Hours/Semester
Assessment Marks
6 96Internal Board Exam Total
25 75 100
Project Work
The students of all the Diploma Programmes (except Diploma in Modern Office Practice) have to do aProject Work as part of the Curriculum and in partial fulfillment for the award of Diploma by the StateBoard of Technical Education and Training, Tamilnadu. In order to encourage students to doworthwhile and innovative projects, every year prizes are awarded for the best three projects i.e.institution wise, region wise and state wise. The selection of Project work should be taken up in VSem. of study. The First Project review should be done in 14th week of study in V Semester. TheSecond Project Review should be done in the 8th week of study in the VI Semester.
a) Internal Assessment mark for Project Work & Viva Voce:
Project Review I (VI SEM ) … 10 marksProject Review II (VI SEM) … 10 marksAttendance 05 marks
-----------Total …. …. … 25 marks
-----------b) Project Work & Viva Voce Board Examination
The allocation of Mark:
Viva Voce … 15 marksProject Report … 10 marksDemonstration … 15 marksApplicability of the Project … 05 marks
------------Total … 45 marks
------------
Written Test in 3 topics for 1 hour:
a) Entrepreneurship 5 questions X 2 marks = 10 marksb) Environment Management5 questions X 2 marks = 10 marksc) Disaster Management 5 questions X 2 marks = 10 marks
------------30 marks------------
Selection of Questions from Question Bank by the External Examiner, no choice need begiven to the candidates.
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2. ENTREPRENEURSHIP 10 Marks
Qualities of an entrepreneurExpectations of entrepreneurshipImportance of SSIAssistances offered to SSIFeasibility studyServices of finance for SSI
3. ENVIRONMENTRAL MANAGEMENT: 10 Marks
(a) Introduction – Environmental Ethics – Assessment of Socio Economic Impact – EnvironmentalAudit – Mitigation of adverse impact on Environment – Importance of Pollution Control –Types of Industries and Industrial Pollution.
(b) Solid waste management – Characteristics of Industrial wastes – Methods of Collection,transfer and disposal of solid wastes – Converting waste to energy – Hazardous wastemanagement Treatment technologies.
(c) Waste water management – Characteristics of Industrial effluents – Treatment and disposalmethods – Pollution of water sources and effects on human health.
(d) Air pollution management – Sources and effects – Dispersion of air pollutants – Air pollutioncontrol methods – Air quality management.
(e) Noise pollution management – Effects of noise on people – Noise control methods.
4. DISASTER MANAGEMENT: 10 Marks
(a) Introduction – Disasters due to natural calamities such as Earthquake, Rain, Flood, Hurricane,Cyclones etc – Man made Disasters – Crisis due to fires, accidents, strikes etc – Loss ofproperty and life.
(b) Disaster Mitigation measures – Causes for major disasters – Risk Identification – H azardZones – Selection of sites for Industries and residential buildings – Minimum distances fromSea – Orientation of Buildings – Stability of Structures – Fire escapes in buildings - Cycloneshelters – Warning systems.
(c) Disaster Management – Preparedness, Response, Recovery – Arrangements to be made inthe industries / factories and buildings – Mobilization of Emergency Services - Search andRescue operations – First Aids – Transportation of affected people – Hospital facilities – Firefighting arrangements – Communication systems – Restoration of Power supply – Gettingassistance of neighbours / Other organizations in Recovery and Rebuilding works – Financialcommitments – Compensations to be paid – Insurances – Rehabilitation.
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LIST OF QUESTIONS
1. ENVIRONMENTRAL MANAGEMENT:
1. What is the responsibility of an Engineer-in-charge of an Industry with respect to Public Health?2. Define Environmental Ethic.3. How Industries play their role in polluting the environment?4. What is the necessity of pollution control? What are all the different organizations you know,
which deals with pollution control?5. List out the different types of pollutions caused by a Chemical / Textile / Leather / Automobile /
Cement factory.6. What is meant by Hazardous waste?7. Define Industrial waste management.8. Differentiate between garbage, rubbish, refuse and trash based on their composition and source.9. Explain briefly how the quantity of solid waste generated in an industry could be reduced.10. What are the objectives of treatments of solid wastes before disposal?11. What are the different methods of disposal of solid wastes?12. Explain how the principle of recycling could be applied in the process of waste minimization.13. Define the term ‘Environmental Waste Audit’.14. List and discuss the factors pertinent to the selection of landfill site.15. Explain the purpose of daily cover in a sanitary landfill and state the minimum desirable depth of
daily cover.16. Describe any two methods of converting waste into energy.17. What actions, a local body such as a municipality could take when the agency appointed for
collecting and disposing the solid wastes fails to do the work continuously for number of days?18. Write a note on Characteristics of hazardous waste.19. What is the difference between municipal and industrial effluent?20. List few of the undesirable parameters / pollutants anticipated in the effluents from oil refinery
industry / thermal power plants / textile industries / woolen mills / dye industries / electroplatingindustries / cement plants / leather industries (any two may be asked)
21. Explain briefly the process of Equalization and Neutralization of waste water of varyingcharacteristics discharged from an Industry.
22. Explain briefly the Physical treatments “Sedimentation” and “Floatation” processes in the wastewater treatment.
23. Explain briefly when and how chemical / biological treatments are given to the waste water.24. List the four common advanced waste water treatment processes and the pollutants they
remove.25. Describe refractory organics and the method used to remove them from the effluent.26. Explain biological nitrification and de-nitrification.27. Describe the basic approaches to land treatment of Industrial Effluent.28. Describe the locations for the ultimate disposal of sludge and the treatment steps needed prior to
ultimate disposal.29. List any five Industries, which act as the major sources for Hazardous Air Pollutants.30. List out the names of any three hazardous air pollutants and their effects on human health.31. Explain the influence of moisture, temperature and sunlight on the severity of air pollution effects
on materials.32. Differentiate between acute and chronic health effects from Air pollution.33. Define the term Acid rain and explain how it occurs.34. Discuss briefly the causes for global warming and its consequences35. Suggest suitable Air pollution control devices for a few pollutants and sources.36. Explain how evaporative emissions and exhaust emissions are commonly controlled.37. What are the harmful elements present in the automobile smokes? How their presence could be
controlled?38. What is the Advantage of Ozone layer in the atmosphere? State few reasons for its destruction.39. Explain the mechanism by which hearing damage occurs.40. List any five effects of noise other than hearing damage.41. Explain why impulsive noise is more dangerous than steady state noise.
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42. Explain briefly the Source – Path – Receiver concept of Noise control.43. Where silencers or mufflers are used? Explain how they reduce the noise.44. Describe two techniques to protect the receiver from hearing loss when design / redress for
noise control fail.45. What are the problems faced by the people residing along the side of a railway track and near to
an Airport? What provisions could be made in their houses to reduce the problem?
2. DISASTER MANAGEMENT:
1. What is meant by Disaster Management? What are the different stages of Disastermanagement?
2. Differentiate Natural Disasters and Man made Disasters with examples.3. Describe the necessity of Risk identification and Assessment Surveys while planning a project.4. What is Disasters recovery and what does it mean to an Industry?5. What are the factors to be considered while planning the rebuilding works after a major disaster
due to flood / cyclone / earthquake? (Any one may be asked)6. List out the public emergency services available in the state, which could be approached for help
during a natural disaster.7. Specify the role played by an Engineer in the process of Disaster management.8. What is the cause for Earthquakes? How they are measured? Which parts of India are more
vulnerable for frequent earthquakes?9. What was the cause for the Tsunami 2004 which inflicted heavy loss to life and property along
the coast of Tamilnadu ? Specify its epicenter and magnitude.10. Specify the Earthquake Hazard Zones in which the following towns of Tamilnadu lie: (a) Chennai
(b) Nagapattinum (c) Coimbatore (d) Madurai (e) Salem.11. Which parts of India are experiencing frequent natural calamities such as (a) heavy rain fall (b)
huge losses due to floods (c) severe cyclones12. Define basic wind speed. What will be the peak wind speed in (a) Very high damage risk zone –
A, (b) High damage risk zone, (c) Low damage risk zone.13. Specify the minimum distance from the Sea shore and minimum height above the mean sea
level, desirable for the location of buildings.14. Explain how the topography of the site plays a role in the disasters caused by floods and
cyclones.15. Explain how the shape and orientation of buildings could reduce the damages due to cyclones.16. What is a cyclone shelter? When and where it is provided? What are its requirements?17. What Precautionary measures have to be taken by the authorities before opening a dam for
discharging the excess water into a canal/river?18. What are the causes for fire accidents? Specify the remedial measures to be taken in buildings
to avoid fire accidents.19. What is a fire escape in multistoried buildings? What are its requirements?20. How the imamates of a multistory building are to be evacuted in the event of a fire/Chemical
spill/Toxic Air Situation/ Terrorist attack, (any one may be asked).21. Describe different fire fighting arrangements to be provided in an Industry.22. Explain the necessity of disaster warning systems in Industries.23. Explain how rescue operations have to be carried out in the case of collapse of buildings due to
earthquake / blast / Cyclone / flood.24. What are the necessary steps to be taken to avoid dangerous epidemics after a flood disaster?25. What relief works that have to be carried out to save the lives of workers when the factory area is
suddenly affected by a dangerous gas leak / sudden flooding?26. What are the difficulties faced by an Industry when there is a sudden power failure? How such a
situation could be managed?27. What are the difficulties faced by the Management when there is a group clash between the
workers? How such a situation could be managed?28. What will be the problems faced by the management of an Industry when a worker dies because
of the failure of a mechanical device due to poor maintenance? How to manage such a situation?
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29. What precautionary measures have to be taken to avoid accidents to labourers in the Industry ina workshop / during handling of dangerous Chemicals / during construction of buildings / duringthe building maintenance works.
30. Explain the necessity of medical care facilities in an Industry / Project site.31. Explain the necessity of proper training to the employees of Industries dealing with hazardous
products, to act during disasters.32. What type of disaster is expected in coal mines, cotton mills, Oil refineries, ship yards and gas
plants?33. What is meant by Emergency Plan Rehearsal? What are the advantages of such Rehearsals?34. What action you will take when your employees could not reach the factory site because of
continuous strike by Public Transport workers?35. What immediate actions you will initiate when the quarters of your factory workers are suddenly
flooded due to the breach in a nearly lake / dam, during heavy rain?36. What steps you will take to avoid a break down when the workers union of your Industry have
given a strike notice?37. List out few possible crisis in an organization caused by its workers? What could be the part of
the middle level officials in managing such crisis?38. What types of warning systems are available to alert the people in the case of predicted
disasters, such as floods, cyclone etc.39. Explain the necessity of Team work in the crisis management in an Industry / Local body.40. What factors are to be considered while fixing compensation to the workers in the case of severe
accidents causing disability / death to them?41. Explain the legal / financial problems the management has to face if safely measures taken by
them are found to be in-adequate.42. Describe the importance of insurance to men and machinery of an Industry dealing with
dangerous jobs.43. What precautions have to be taken while storing explosives in a match/ fire crackers factory?44. What are the arrangements required for emergency rescue works in the case of Atomic Power
Plants?45. Why residential quarters are not constructed nearer to Atomic Power Plants?
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SANDWICH DIPLOMA COURSE - INDUSTRIAL TRAINING
12047 INDUSTRIAL TRAINING -I12067 INDUSTRIAL TRAINING -II
1. Introduction
The main objective of the sandwich Diploma Course is to mould a well rounded technician acclimatedwith industrial environment while being a student in the institution.
The Sandwich Diploma Course study is pursued by students, in 7 semesters of 3½ years duration,the subjects of 3 years - Full Time Diploma Course being regrouped for academic convenience.
While in the 4th semester students under Industrial Training for 6 months (December through May ).They also do course work in the institution for one day in a week, While in the 7th semester theyundergo another spell of 6 months (June through November ) industrial training.
The Apprenticeship (Amendment) Act 1973 is followed in regulating the Industrial training procedurefor Sandwich Course.
I SEM II SEM III SEM IV SEM V SEM VI SEM VII SEM
First Spell - IV Semester (December - May)Second Spell - VII Semester (June - November)
2. Attendance Certification
Every month students have to get their attendance certified by industrial supervisor in the prescribedform supplied to them. Students have also to put their signature on the form and submit it to theinstitution supervisor. Regularity in attendance and submission of report will be duly considered whileawarding the sessional mark.
3. Training Reports
The students have to prepare two types of reports: Weekly report in the form of diary to be submitted to the concerned staff incharge of the
institution. This will be reviewed while awarding sessional marks. Comprehensive report at the end of each spell which will be used for Board Examination.
3.1 Industrial Training Diary
Students are required to maintain the record of day - to- day work done. Such record is calledIndustrial training Diary. Students have to write this reports regularly. All days for the week should beaccounted for clearly giving attendance particulars (Presence, Absence, Leave, Holidays etc). Theconcern Industrial supervisor is to check periodically these progress reports.
Institutional study
Industrial Training
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3.2 Comprehensive Training Report
In addition to the diary, students are required to submit a comprehensive report on training withdetails of the organisation where the training was undergone after attestation by the supervisors. Thecomprehensive report should be incorporating study of plant/ product /process/ construction alongwith intensive in-depth study on any one of the topics such as precesses, methods, tooling,construction and equipment, highlighting aspects of quality, productivity and system. Thecomprehensive report should be completed in the last week of Industrial training. Any data, drawingsetc should be incorporated with the consent of the Organisation.
4. Scheme of Evaluation
4.1 Sessional Marks
First review (during 3rd month) : 10 marksSecond review (during 5th month) : 10 marksAttendance : 05 marks (Awarded same as in Theory)
Total : 25 marks
4.2 Board Examination
Presentation about Industrial Training : 20 marksComprehensive Training Report : 30 marksViva-voce : 25 marks
